07 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
2 THE CHEMISTRY .................................................................................................. 4
2.1 ALKYLATION ....................................................................................................... 4
2.2 DEHYDROGENATION ............................................................................................ 6
2.3 POLYMERIZATION ................................................................................................ 7
3 OBJECTIVES ........................................................................................................... 8
4 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
5 ENVIRONMENTAL, HEALTH AND SAFETY ISSUES.................................. 25
5.1 ENVIRONMENTAL CONCERNS ............................................................................ 25
5.2 CHEMICAL HAZARDS ......................................................................................... 26
5.3 SAFETY HAZARDS .............................................................................................. 27
6 CONTROL DESIGN .............................................................................................. 28
6.1 CONTROL DESIGN ON AREA 100........................................................................ 28
7 ECONOMIC ANALYSIS ...................................................................................... 32
8 UNCERTAINTIES AND ASSUMPTIONS.......................................................... 34
9 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)
(Rxn 2b)
H2
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 n-
propylbenzene 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 non-
optimized.
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 R-
100, 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
y = 498.18x-0.6678
R 2 = 0.9967
g/h/kgcat
150
100
50
y = 17.28x0.5396
R 2 = 0.9996
0
0 2 4 6 8 10 12
Ethane/EB vol
Figure 1: Weight of Catalyst vs. Ethane and Ethylbenzene Volumetric Ratio

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. T-
300 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 T-
301.
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. T-
301 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 T-
303, 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 E-
202.1. 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 Area-
100, 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 graphite-
like 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 T-
201 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 non-
overlapping 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 R-
100. 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 Area-
300 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 E-
200, 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 T-
200 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%
20.0%
IRR
15.0%
10.0%
5.0%
0.0%
$0.70 $0.80 $0.90 $1.00 $1.10 $1.20 $1.30 $1.40
-5.0%
Styrene Monomer Product Price ($/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:
n
CFi
0= (Equation 2)
i=0 (1 + IRR) i
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.

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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
ID Number: K-200.1 Date: 5/8/2006
Description: Dehydrogenation Feed Compressor Train Prepared By: ACJ
No. Required 1 Checked By: MJH
Fluid Properties
3
Process Feed Flow Rate (m /hr) 418300
Ethane 0.8452
n-Hexane 0.0001
1 Meta 3 Ethyl Benzene 0.0000
Toluene 0.0003
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
Cumene 0.0001
n-Propyl Benzene 0.0000
Alpha Metal Styrene 0.0000
Meta Diethyl Benzene 0.0000
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: K-200.2 Date: 5/8/2006
Fluid Properties
3
Ethane 0.8452
n-Hexane 0.0001
Toluene 0.0003
Benzene 0.0000
Hydrogen 0.0000
Oxygen 0.0000
Water 0.0000
Ethylene 0.0000
Styrene 0.0000
Cumene 0.0001
ID Number: K-200.3 Date: 5/8/2006
Fluid Properties
3
Ethane 0.8452
n-Hexane 0.0001
Toluene 0.0003
Benzene 0.0000
Hydrogen 0.0000
Oxygen 0.0000
Water 0.0000
Ethylene 0.0000
Styrene 0.0000
Cumene 0.0001
ID Number: K-201 Date: 5/8/2006
Description: Air Feed Compressor Prepared By: ACJ
Fluid Properties
3
Ethane 0.0000
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.0000
Oxygen 0.2100
Water 0.0000
Ethylene 0.0000
Styrene 0.0000
Cumene 0.0000
ID Number: K-202.1 Date: 5/8/2006
Description: Recycle Stream Compressor Train Prepared By: ACJ
Fluid Properties
3
Ethane 0.0000
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.0000
Oxygen 0.0000
Water 0.0246
Ethylene 0.0000
Styrene 0.0000
Cumene 0.0000
ID Number: K-202.2 Date: 5/8/2006
Description: Recycle Stream Compressor Train Prepared By: ACJ
Fluid Properties
3
Ethane 0.0000
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.0000
Oxygen 0.0000
Water 0.0246
Ethylene 0.0000
Styrene 0.0000
Cumene 0.0000
Description: Ethyl Benzene Recycle Stream Compressor Prepared By: ACJ
Fluid Properties
3
Ethane 0.0000
n-Hexane 0.0000
Toluene 0.0041
Benzene 0.0000
Hydrogen 0.0000
Oxygen 0.0000
Water 0.0000
Ethylene 0.0000
Styrene 0.0002
Cumene 0.0000
Description: Light Gases Stream Compressor Train Prepared By: ACJ
Fluid Properties
3
Ethane 0.5804
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.1199
Oxygen 0.0000
Water 0.0000
Ethylene 0.0630
Styrene 0.0000
Cumene 0.0000
Inlet Temperature (C) -50.0
Outlet Temperature (C) -28.1
Material of Construction Stainless Steel
ID Number: K-401.1 Date: 5/8/2006
Fluid Properties
3
Ethane 0.5804
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.1199
Oxygen 0.0000
Water 0.0000
Ethylene 0.0630
Styrene 0.0000
Cumene 0.0000
ID Number: K-401.2 Date: 5/8/2006
Fluid Properties
3
Ethane 0.5804
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.1199
Oxygen 0.0000
Water 0.0000
Ethylene 0.0630
Styrene 0.0000
Cumene 0.0000
ID Number: K-401.3 Date: 5/8/2006
Fluid Properties
3
Ethane 0.5804
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.1199
Oxygen 0.0000
Water 0.0000
Ethylene 0.0630
Styrene 0.0000
Cumene 0.0000
ID Number: K-401.4 Date: 5/8/2006
Fluid Properties
3
Ethane 0.5804
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.1199
Oxygen 0.0000
Water 0.0000
Ethylene 0.0630
Styrene 0.0000
Cumene 0.0000
ID Number: K-401.5 Date: 5/8/2006
Fluid Properties
3
Ethane 0.5804
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.1199
Oxygen 0.0000
Water 0.0000
Ethylene 0.0630
Styrene 0.0000
Cumene 0.0000
ID Number: K-401.6 Date: 5/8/2006
Fluid Properties
3
Ethane 0.5804
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.1199
Oxygen 0.0000
Water 0.0000
Ethylene 0.0630
Styrene 0.0000
Cumene 0.0000
ID Number: K-402.1 Date: 5/8/2006
Fluid Properties
3
Ethane 0.5550
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.1277
Oxygen 0.0000
Water 0.0000
Ethylene 0.0650
Styrene 0.0000
Cumene 0.0000
ID Number: K-402.2 Date: 5/8/2006
Fluid Properties
3
Ethane 0.5550
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.1277
Oxygen 0.0000
Water 0.0000
Ethylene 0.0650
Styrene 0.0000
Cumene 0.0000
ID Number: K-402.3 Date: 5/8/2006
Fluid Properties
3
Ethane 0.5550
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.1277
Oxygen 0.0000
Water 0.0000
Ethylene 0.0650
Styrene 0.0000
Cumene 0.0000
ID Number: K-402.4 Date: 5/8/2006
Fluid Properties
3
Ethane 0.5550
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.1277
Oxygen 0.0000
Water 0.0000
Ethylene 0.0650
Styrene 0.0000
Cumene 0.0000
ID Number: K-402.5 Date: 5/8/2006
Fluid Properties
3
Ethane 0.5550
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.1277
Oxygen 0.0000
Water 0.0000
Ethylene 0.0650
Styrene 0.0000
Cumene 0.0000
ID Number: K-403.1 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0173
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.2374
Oxygen 0.0000
Water 0.0000
Ethylene 0.1215
Styrene 0.0000
Cumene 0.0000
ID Number: K-403.2 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0173
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.2374
Oxygen 0.0000
Water 0.0000
Ethylene 0.1215
Styrene 0.0000
Cumene 0.0000
ID Number: K-403.3 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0173
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.2374
Oxygen 0.0000
Water 0.0000
Ethylene 0.1215
Styrene 0.0000
Cumene 0.0000
ID Number: K-404.1 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0968
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.2591
Oxygen 0.0000
Water 0.0000
Ethylene 0.1326
Styrene 0.0000
Cumene 0.0000

ID Number: K-404.2 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0968
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.2591
Oxygen 0.0000
Water 0.0000
Ethylene 0.1326
Styrene 0.0000
Cumene 0.0000

ID Number: K-404.3 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0968
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.2591
Oxygen 0.0000
Water 0.0000
Ethylene 0.1326
Styrene 0.0000
Cumene 0.0000

ID Number: K-405.1 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0428
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.2783
Oxygen 0.0000
Water 0.0000
Ethylene 0.1296
Styrene 0.0000
Cumene 0.0000

ID Number: K-405.2 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0428
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.2783
Oxygen 0.0000
Water 0.0000
Ethylene 0.1296
Styrene 0.0000
Cumene 0.0000

ID Number: K-405.3 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0428
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.2783
Oxygen 0.0000
Water 0.0000
Ethylene 0.1296
Styrene 0.0000
Cumene 0.0000

ID Number: K-406.1 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0280
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.2973
Oxygen 0.0000
Water 0.0000
Ethylene 0.0880
Styrene 0.0000
Cumene 0.0000

ID Number: K-406.2 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0280
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.2973
Oxygen 0.0000
Water 0.0000
Ethylene 0.0880
Styrene 0.0000
Cumene 0.0000

ID Number: K-406.3 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0280
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.2973
Oxygen 0.0000
Water 0.0000
Ethylene 0.0880
Styrene 0.0000
Cumene 0.0000

ID Number: K-407.1 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0159
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.3133
Oxygen 0.0000
Water 0.0000
Ethylene 0.0525
Styrene 0.0000
Cumene 0.0000

ID Number: K-407.2 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0159
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.3133
Oxygen 0.0000
Water 0.0000
Ethylene 0.0525
Styrene 0.0000
Cumene 0.0000

ID Number: K-407.3 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0159
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.3133
Oxygen 0.0000
Water 0.0000
Ethylene 0.0525
Styrene 0.0000
Cumene 0.0000

ID Number: K-408.1 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0074
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.3252
Oxygen 0.0000
Water 0.0000
Ethylene 0.0258
Styrene 0.0000
Cumene 0.0000

ID Number: K-408.2 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0074
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.3252
Oxygen 0.0000
Water 0.0000
Ethylene 0.0258
Styrene 0.0000
Cumene 0.0000

ID Number: K-408.3 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0074
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.3252
Oxygen 0.0000
Water 0.0000
Ethylene 0.0258
Styrene 0.0000
Cumene 0.0000

ID Number: K-409.1 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0026
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.3322
Oxygen 0.0000
Water 0.0000
Ethylene 0.0097
Styrene 0.0000
Cumene 0.0000

ID Number: K-409.2 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0026
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.3322
Oxygen 0.0000
Water 0.0000
Ethylene 0.0097
Styrene 0.0000
Cumene 0.0000

ID Number: K-409.3 Date: 5/8/2006
Fluid Properties
3
Ethane 0.0026
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.3322
Oxygen 0.0000
Water 0.0000
Ethylene 0.0097
Styrene 0.0000
Cumene 0.0000

Fluid Properties
3
Ethane 0.0008
n-Hexane 0.0000
Toluene 0.0000
Benzene 0.0000
Hydrogen 0.3350
Oxygen 0.0000
Water 0.0000
Ethylene 0.0031
Styrene 0.0000
Cumene 0.0000

A.2: Heat Exchanger Specifications (1 of 61)
Heat Exchanger Specifications
ID Number: E-100 Date: 5/9/2006
Description: Ethane/Ethylene Return Heater
Prepared By: ACJ
Unit Performance & Fluid Properties
Tube Side Shell Side
Inlet Outlet Inlet Outlet
Fluid Process Streams Exhaust Steam
Flow Rate - Vapor (kg/hr) 0 366000 121640 0
Flow Rate - Liquid (kg/hr) 366000 0 0 121640
Temperature (C) -120 25 111 111
Pressure (kPa) 101 101 150 147
3
Density (kg/m ) 584 1.22 0.85 52.08
Viscosity - Vapor (cP) 0.0000 0.0095 0.0125 0.0000
Viscosity - Liquid (cP) 0.2517 0.0000 0.0000 0.2490
Specific Heat (J/mol-K) 72.03 51.96 39.87 75.92
Thermal Conductivity - Vapor (W/m-K) 0.0000 0.0213 0.0254 0.0000
Thermal Conductivity - Liquid (W/m-K) 0.1840 0.0000 0.0000 0.6847
Duty (MJ/hr) Total Heat Transfer Area (m2) Heat Flux (kJ/hr-m2-K)
270680 391 4697
Unit Construction
Number of Passes 2 1
Material of Construction Carbon Steel Carbon Steel
ID Number: T-100C Date: 5/9/2006
Description: Column T-100 Condenser
Prepared By: ACJ
Fluid Process Streams Cooling Water
Temperature (C) 148 148 15 111
Pressure (kPa) 136 133 150 147
3
Density (kg/m ) 4.12 4.12 1015.00 0.85
122700 955 966
Unit Construction
ID Number: T-100R Date: 5/9/2006
Description: Column T-100 Reboiler
Prepared By: ACJ
Fluid Process Streams High Pressure Steam
Temperature (C) 194 194 243 243
Pressure (kPa) 136 133 3550 3547
3
Density (kg/m ) 714 714 14.89 804
164800 1922 1736
Unit Construction
ID Number: R-100C Date: 5/9/2006
Description: Column R-100 Condenser
Prepared By: ACJ
Pressure (kPa) 136 133 150 147
3
Density (kg/m ) 4.12 4.12 1015.00 0.85
30675 239 966
Unit Construction
ID Number: R-100R Date: 5/9/2006
Description: Column R-100 Reboiler
Prepared By: ACJ
Fluid Process Streams High Pressure Steam
Temperature (C) 194 194 243 243
Pressure (kPa) 136 133 3550 3547
3
Density (kg/m ) 714 714 14.89 804
41200 480 1736
Unit Construction
Description: Dehydrogenation Feed Vaporizer
Prepared By: ACJ
Pressure (kPa) 105 102 150 147
3
Density (kg/m ) 1.72 1.47 0.85 52.08
66020 1059 1546
Unit Construction
Material of Construction Stainless Steel Carbon Steel
Dehydrogenation Feed Heater/Product
Description:
Cooler Prepared By: ACJ
Fluid Process Streams Process Streams
Temperature (C) 129 420 600 388
Pressure (kPa) 263 260 133 130
3
Density (kg/m ) 3.29 1.91 0.63 0.81
443300 3387 800
Unit Construction
Material of Construction Stainless Steel Stainless Steel
ID Number: E-202.1 Date: 5/9/2006
Description: Nitrogen Recycle Stream Cooler
Prepared By: ACJ
Pressure (kPa) 187 184 220 217
3
Density (kg/m ) 1.83 2.02 1015 988
9494 176 1610
Unit Construction
ID Number: E-202.2 Date: 5/9/2006
Prepared By: ACJ
Fluid Process Streams R-22
Temperature (C) 75 -50 -60 -5
Pressure (kPa) 265 262 220 217
Density (kg/m3) 2.55 0.14 1465 8.53
40860 310 1609
Unit Construction
Dehydrogenation Startup/Control
Description:
Exchanger Prepared By: ACJ
Fluid Process Streams Used For Start Up
Pressure (kPa) 260 257 0 0
3
Density (kg/m ) 1.67 1.67 0 0
Viscosity - Vapor (cP) 0.0242 0.0242 0 0
Viscosity - Liquid (cP) 0.0000 0.0000 0 0
Specific Heat (J/mol-K) 105.00 105.00 0 0
Thermal Conductivity - Vapor (W/m-K) 0.0716 0.0716 0 0
Thermal Conductivity - Liquid (W/m-K) 0.0000 0.0000 0 0
0 803 0
Unit Construction
Description: Separations Feed Stream Cooler
Prepared By: ACJ
Temperature (C) 388 320 -50 846
Pressure (kPa) 130 127 262 259
3
Density (kg/m ) 0.81 0.88 3.95 0.79
125500 253 1032
Unit Construction
Description: Separations Feed Stream Cooler
Prepared By: ACJ
Pressure (kPa) 126 123 220 217
Density (kg/m3) 0.87 2.58 1465 8.53
616400 2438 1610
Unit Construction
Prepared By: ACJ
Pressure (kPa) 130 127 220 217
Density (kg/m3) 0.23 1.66 1015 988
34360 676 410
Unit Construction
Description: Nitrogen/Light Gases Exchanger
Prepared By: ACJ
Pressure (kPa) 135 133 132 130
3
Density (kg/m ) 1.05 0.38 0.55 0.89
97430 208 1037
Unit Construction
Description: Nitrogen/Air Exchanger
Prepared By: ACJ
Pressure (kPa) 136 133 134 131
3
Density (kg/m ) 1.42 0.56 0.43 0.55
81250 283 1052
Unit Construction
Description: Distillation Chain Feed Heater
Prepared By: ACJ
Temperature (C) -50 40 111 111
Pressure (kPa) 101 101 220 217
Density (kg/m3) 878 73.06 0.85 52.08
36680 584 569
Unit Construction
Description: Styrene Product Condenser
Prepared By: ACJ
3
Density (kg/m ) 0.20 885 1015 1001
48142 5675 366
Unit Construction
Prepared By: ACJ
Pressure (kPa) 27 27 220 217
3
Density (kg/m ) 0.82 0.82 1015 996
39440 1697 778
Unit Construction
Prepared By: ACJ
Pressure (kPa) 27 27 220 217
3
Density (kg/m ) 818 818 0.85 52.08
66390 3903 1073
Unit Construction
Prepared By: ACJ
Pressure (kPa) 27 27 220 217
3
Density (kg/m ) 0.80 0.80 1015 1004
5194 370 780
Unit Construction
Prepared By: ACJ
Pressure (kPa) 27 27 220 217
3
Density (kg/m ) 822 822 0.85 52.08
3552 79 1076
Unit Construction
Prepared By: ACJ
Pressure (kPa) 27 27 220 217
3
Density (kg/m ) 0.90 0.90 1015 1005
2768 453 612
Unit Construction
Prepared By: ACJ
Pressure (kPa) 27 27 220 217
3
Density (kg/m ) 854 854 0.85 52.08
1284 17 1080
Unit Construction
Prepared By: ACJ
3
Density (kg/m ) 0.30 0.30 1015 1004
431700 11301 987
Unit Construction
Prepared By: ACJ
3
Density (kg/m ) 861 861 0.85 52.08
461800 10431 1063
Unit Construction
Prepared By: ACJ
3
Density (kg/m ) 0.20 0.20 1015 995
23770 1046 755
Unit Construction
Prepared By: ACJ
3
Density (kg/m ) 869 869 0.85 52.08
53210 977 1073
Unit Construction
Prepared By: ACJ
3
Density (kg/m ) 0.20 0.20 1015 995
13900 611 756
Unit Construction
Prepared By: ACJ
3
Density (kg/m ) 869 869 0.85 52.08
24640 453 1075
Unit Construction
Prepared By: ACJ
3
Density (kg/m ) 0.20 0.20 1015 995
40140 1781 748
Unit Construction
Prepared By: ACJ
3
Density (kg/m ) 838 838 0.85 52.08
42820 239 4707
Unit Construction
Description: Light Gases Cooler
Prepared By: ACJ
Temperature (C) -28 -47 -60 -50
Pressure (kPa) 174 171 220 217
3
Density (kg/m ) 2.22 2.41 1465 1437
14580 777 1615
Unit Construction
Prepared By: ACJ
Temperature (C) -2 -25 -60 -50
Pressure (kPa) 3003 3000 220 217
3
Density (kg/m ) 34.71 38.00 1465 1437
18600 1530 311
Unit Construction
ID Number: E-401.1 Date: 5/9/2006
Prepared By: ACJ
Temperature (C) -30 -50 -60 -35
Pressure (kPa) 187 184 220 217
3
Density (kg/m ) 2.42 2.59 1465 1394
14920 429 1615
Unit Construction
ID Number: E-401.2 Date: 5/9/2006
Prepared By: ACJ
Temperature (C) -13 -50 -60 -18
Pressure (kPa) 325 322 220 217
3
Density (kg/m ) 3.92 4.53 1465 8.95
28470 447 1615
Unit Construction
ID Number: E-401.3 Date: 5/9/2006
Prepared By: ACJ
Temperature (C) -13 -50 -60 -18
Pressure (kPa) 568 565 220 217
3
Density (kg/m ) 6.85 7.95 1465 8.95
28470 447 1615
Unit Construction
ID Number: E-401.4 Date: 5/9/2006
Prepared By: ACJ
Temperature (C) -13 -48 -60 -43
Pressure (kPa) 997 994 220 217
3
Density (kg/m ) 12.01 13.89 1465 1418
26740 886 1656
Unit Construction
ID Number: E-401.4 Date: 5/9/2006
Prepared By: ACJ
Temperature (C) -11 -38 -60 -16
Pressure (kPa) 1750 1747 220 217
3
Density (kg/m ) 20.92 23.36 1465 8.89
21340 385 1615
Unit Construction
Prepared By: ACJ
Pressure (kPa) 3003 3000 220 217
3
Density (kg/m ) 33.45 36.02 1465 8.53
14840 323 1588
Unit Construction
ID Number: E-402.2 Date: 5/9/2006
Prepared By: ACJ
Pressure (kPa) 444 441 220 217
3
Density (kg/m ) 5.21 6.14 1465 8.82
29230 418 1616
Unit Construction
ID Number: E-402.3 Date: 5/9/2006
Prepared By: ACJ
Pressure (kPa) 846 843 220 217
3
Density (kg/m ) 9.85 11.73 1465 8.74
31010 420 1615
Unit Construction
ID Number: E-402.4 Date: 5/9/2006
Prepared By: ACJ
Pressure (kPa) 1617 1614 220 217
3
Density (kg/m ) 18.83 21.28 1465 8.74
21990 359 1612
Unit Construction
Prepared By: ACJ
Pressure (kPa) 3000 2997 220 217
3
Density (kg/m ) 26.03 35.86 1465 8.53
27610 256 1617
Unit Construction
ID Number: E-403.1 Date: 5/9/2006
Prepared By: ACJ
Temperature (C) -27 -50 -60 -32
Pressure (kPa) 397 394 220 217
3
Density (kg/m ) 4.30 4.71 1465 1384
7408 183 1609
Unit Construction
ID Number: E-403.2 Date: 5/9/2006
Prepared By: ACJ
Pressure (kPa) 1088 1085 220 217
3
Density (kg/m ) 9.44 12.99 1465 8.53
27610 257 1609
Unit Construction
Prepared By: ACJ
Pressure (kPa) 3000 2997 220 217
3
Density (kg/m ) 24.98 34.70 1465 8.53
24970 229 1610
Unit Construction
ID Number: E-404.1 Date: 5/9/2006
Prepared By: ACJ
Temperature (C) -32 -50 -60 -37
Pressure (kPa) 410 407 220 217
3
Density (kg/m ) 4.38 4.71 1465 16.18
168 160 53
Unit Construction
ID Number: E-404.2 Date: 5/9/2006
Prepared By: ACJ
Pressure (kPa) 1106 1103 220 217
3
Density (kg/m ) 9.21 12.77 1465 8.53
24970 229 1610
Unit Construction
Prepared By: ACJ
Pressure (kPa) 3000 2997 220 217
3
Density (kg/m ) 24.17 33.71 1465 8.53
22790 207 1610
Unit Construction
ID Number: E-405.1 Date: 5/9/2006
Prepared By: ACJ
Temperature (C) -39 -50 -60 -45
Pressure (kPa) 427 424 220 217
3
Density (kg/m ) 4.60 4.77 1465 1423
2571 145 1570
Unit Construction
ID Number: E-405.2 Date: 5/9/2006
Prepared By: ACJ
Pressure (kPa) 1130 1127 220 217
3
Density (kg/m ) 9.10 12.67 1465 8.53
22790 207 1610
Unit Construction
Prepared By: ACJ
Pressure (kPa) 3000 2997 220 217
3
Density (kg/m ) 23.44 32.86 1465 8.53
21140 191 1608
Unit Construction
ID Number: E-406.1 Date: 5/9/2006
Prepared By: ACJ
Temperature (C) -43 -50 -60 -48
Pressure (kPa) 436 433 220 217
3
Density (kg/m ) 4.64 4.75 1465 1432
1605 145 1627
Unit Construction
ID Number: E-406.2 Date: 5/9/2006
Prepared By: ACJ
Pressure (kPa) 1142 1139 220 217
3
Density (kg/m ) 8.92 12.48 1465 8.53
21140 191 1608
Unit Construction
Prepared By: ACJ
Pressure (kPa) 3000 2997 220 217
3
Density (kg/m ) 22.86 32.15 1465 8.53
19800 178 1607
Unit Construction
ID Number: E-407.1 Date: 5/9/2006
Prepared By: ACJ
Pressure (kPa) 448 445 220 217
3
Density (kg/m ) 4.76 4.77 1465 8.53
448 10 1735
Unit Construction
Prepared By: ACJ
Pressure (kPa) 3000 2997 220 217
3
Density (kg/m ) 22.55 31.62 1465 8.53
18540 167 1608
Unit Construction
ID Number: E-407.2 Date: 5/9/2006
Prepared By: ACJ
Pressure (kPa) 448 445 220 217
3
Density (kg/m ) 8.82 12.38 1465 8.53
19800 178 1607
Unit Construction
ID Number: E-408.1 Date: 5/9/2006
Prepared By: ACJ
Pressure (kPa) 1187 1184 220 217
3
Density (kg/m ) 9.09 12.49 1465 8.53
17340 162 1610
Unit Construction
Prepared By: ACJ
Pressure (kPa) 3000.0 2997.0 220.0 217.0
3
Density (kg/m ) 22.52 31.31 1465 8.53
17420 127 2029
Unit Construction
ID Number: E-409.2 Date: 5/9/2006
Prepared By: ACJ
Pressure (kPa) 1228 1225 220 217
3
Density (kg/m ) 9.73 12.80 1465 8.53
14140 143 1612
Unit Construction
A.3: Pump Specifications (1 of 4)
Pump Specifications
ID Number: P-100 Date: 5/8/2006
Description: Benzene Feed Pump Prepared By: MJH
No. Required 1 Checked By: JRB
Fluid Properties
Process Fluid Mass Flow Rate (kg/hr) 88117
99.85% Benzene
Process Fluid Compsition (mol%) 0.1% n-Hexane
0.05% Toluene
Pump Type Centrifugal
Material of Construction Cast Iron
Design Pressure (kPa) 4000 (max)
Design Temperature (C) 300 (max)
Pump Efficiency (%) 75
Hydraulic Power (hp) 1.9
Brake Power (hp) 2.5
Pump Specifications
Description: Benzene Recycle Pump Prepared By: MJH
Fluid Properties
99.85% Benzene
Process Fluid Compsition (mol%) 0.14% n-Hexane
0.01% Toluene
Pump Specifications
Description: Toluene Product Pump Prepared By: MJH
Fluid Properties
99.75% Toluene
Process Fluid Compsition (mol%) 0.24% Ethylbenzene
0.01% Benzene
Pump Specifications
Description: Styrene Product Pump Prepared By: MJH
Fluid Properties
99.93% Styrene
Process Fluid Compsition (mol%) 0.04% Cumene
0.01% Toluene
Trace Heavies
A.4: Tank Specifications (1 of 8)
Tank Specifications
ID Number: Tank-100 Date: 5/8/2006
Description: Styrene Monomer Product Tank Prepared By: MJH
No. Required 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
Vessel Orientation Vertical
Design Temperature (C) 480 (max) Agitation Required? N
Design Pressure (kPa) 4000 (max) Power (hp) NA
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
Tank Specifications
Description: Styrene Monomer Off-Specification Tank Prepared By: MJH
Fluid Composition (by mass) <99.93% Styrene Monomer
Operating Temperature (C) 23.9
Service Volume (m3) 6,008
Type Cone Roof
Tank Height (m) 25 Heat Exchange? Y
Residence Time (days) 2 Type External Cooler
Liquid Level (%) 85 Media H2O
Media Flowrate (kg/s) 11.2
Area (m2) 189
Tank Specifications
Description: Benzene Feed Tank Prepared By: MJH
Fluid Composition (by mass) >99.8% Benzene
Operating Temperature (C) Atmospheric
3
Service Volume (m ) 9,026
Type Cone Roof
Tank Height (m) 34 Heat Exchange? N
Residence Time (days) 30 Type NA
Liquid Level (%) 85 Media NA
Media Flowrate NA
Area (m2) NA
Tank Specifications
Description: Benzene Off-Specification Tank Prepared By: MJH
Fluid Composition (by mass) <99.8% Benzene
3
Type Cone Roof
Tank Height (m) 29.5 Heat Exchange? N
Media Flowrate NA
Area (m2) NA
Tank Specifications
Description: Ethylbenzene Startup Tank Prepared By: MJH
Fluid Composition (by mass) ~99.8% Ethylbenzene
3
Type Cone Roof
Media Flowrate NA
Area (m2) NA
Tank Specifications
Description: Ethylbenzene Off-Specification Tank Prepared By: MJH
Fluid Composition (by mass) <99.8% Ethylbenzene
3
Type Cone Roof
Media Flowrate NA
Area (m2) NA
Tank Specifications
Description: Toluene Product Storage Tank Prepared By: MJH
Fluid Composition (by mass) >99.7% Toluene
3
Type Cone Roof
Media Flowrate NA
Area (m2) NA
Tank Specifications
Description: Toluene Off-Spec Storage Tank Prepared By: MJH
Fluid Composition (by mass) <99.7% Toluene
3
Service Volume (m ) 236
Type Cone Roof
Design Volume (m3) 261 Impeller Diameter (m) NA
Tank Diameter (m) 5.5 Max Speed (rpm) NA
Tank Height (m) 11 Heat Exchange? N
Media Flowrate NA
Area (m2) NA
A.5: Two Phase Separator Specifications (1 of 13)
Two-Phase Separator Specifications
ID Number: V-100 Date: 5/11/2006
Description: Two-Phase Separator Prepared By: LJB
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%)
Ethylbenzene (45.2%), Styrene (44.7%), Ethane (5.6%),

Liquid Effluent 2409 kgmol/hr Toluene (2.1%), Benzene (1.9%)
Trace: n-Hexane, Nitrogen, Heavies
Inlet Exit
Temperature (C) -50.0 Temperature (C) -50.0
Pressure (kPa) 124.0 Pressure (kPa) 124.0
Design Data
Type Two Phase Separator
Position Vertical
Height (m) 9.07
Diameter (m) 2.59
Volume (m3) 47.79
Additional Equipment
Heat Exchange Required? N Agitation Required? N
Inlet Flows
Nitrogen (79.2%), Water (20.4%)
Vapor Feed 10380 kgmol/hr Trace: Carbon Dioxide
Outlet Flows
Vapor Effluent 8477 kgmol/hr Trace: Carbon Dioxide
Water (100%)
Liquid Effluent 1904 kgmol/hr
Inlet Exit
Temperature (C) 25.0 Temperature (C) 25.0
Design Data
Position Vertical
Height (m) 6.93
Diameter (m) 1.98
Volume (m3) 21.34
Inlet Flows
Vapor Feed 8477 kgmol/hr Trace: Carbon Dioxide
Outlet Flows
Nitrogen (99.4%)
Water (100%)
Liquid Effluent 208.5 kgmol/hr Trace: Carbon Dioxide
Inlet Exit
Design Data
Position Vertical
Height (m) 4.27
Diameter (m) 1.22
Volume (m3) 4.99
Inlet Flows
Ethane (58.0 mol%), Nitrogen (23.7%), Hydrogen (12.0%),
Vapor Feed 19080 kgmol/hr Ethylene (6.3%)
Outlet Flows
Inlet Exit
Design Data
Position Vertical
Height (m) 9.60
Diameter (m) 2.74
Volume (m3) 56.61
Inlet Flows
Outlet Flows
Ethane (97.3%), Ethylene (2.7%)

Liquid Effluent 1161 kgmol/hr Trace: Benzene, Nitrogen
Inlet Exit
Design Data
Position Vertical
Height (m) 8.00
Diameter (m) 2.29
Volume (m3) 32.95
Inlet Flows
Outlet Flows
Vapor Effluent 9642 kgmol/hr Ethylene 12.2%)
Ethane (100%)
Inlet Exit
Design Data
Position Vertical
Height (m) 9.60
Diameter (m) 2.74
Volume (m3) 56.61
Inlet Flows
Vapor Feed 9642 kgmol/hr Ethylene 12.2%)
Outlet Flows
Nitrogen (51.1%), Hydrogen (25.9%), Ethylene (13.3%)
Vapor Effluent 8831 kgmol/hr Ethane (9.7 mol%)
Ethane (100%)
Liquid Effluent 810.2 kgmol/hr
Inlet Exit
Design Data
Position Vertical
Height (m) 5.87
Diameter (m) 1.68
Volume (m3) 13.01
Inlet Flows
Vapor Feed 8831 kgmol/hr Ethane (9.7%)
Outlet Flows
Vapor Effluent 8222kgmol/hr Ethane (4.3%)
Ethane (82.6%), Ethylene (17.4%)

Inlet Exit
Design Data
Position Vertical
Height (m) 5.30
Diameter (m) 1.52
Volume (m3) 9.62
Inlet Flows
Vapor Feed 8222kgmol/hr Ethane (4.3%)
Outlet Flows
Vapor Effluent 7697 kgmol/hr Ethane (2.8%)
Ethylene (74.0%), Ethane (26.0%),

Inlet Exit
Design Data
Position Vertical
Height (m) 5.33
Diameter (m) 1.52
Volume (m3) 9.67
Inlet Flows
Outlet Flows
Vapor Effluent 7304 kgmol/hr Ethane (1.6%)

Inlet Exit
Design Data
Position Vertical
Height (m) 4.80
Diameter (m) 1.37
Volume (m3) 7.08
Inlet Flows
Outlet Flows
Vapor Effluent 7038 kgmol/hr Trace: Ethane

Inlet Exit
Design Data
Position Vertical
Height (m) 4.80
Diameter (m) 1.37
Volume (m3) 7.08
Inlet Flows
Vapor Feed 7038 kgmol/hr Trace: Ethane
Outlet Flows
Nitrogen (65.6%), Hydrogen (33.2%)
Vapor Effluent 6890 kgmol/hr Trace: Ethylene, Ethane

Inlet Exit
Design Data
Position Vertical
Height (m) 4.80
Diameter (m) 1.37
Volume (m3) 7.08
Inlet Flows
Vapor Feed 6890 kgmol/hr Trace: Ethylene, Ethane
Outlet Flows
Vapor Effluent 6832 kgmol/hr Trace: Ethylene, Ethane

Inlet Exit
Design Data
Position Vertical
Height (m) 4.27
Diameter (m) 1.22
Volume (m3) 4.99
A.6: Turbine Specifications (1 of 10)
Turbine Specifications
ID Number: M-400 Date: 5/8/2006
Description: 1st Turbine Prepared By: MJH
No. Required 1 Checked By: LJB
Fluid Properties
Process Feed Flow Rate (kg/hr) 497960
58.04% Ethane
23.67% Nitrogen
Vapor Composition (mol%) 11.99% Hydrogen
6.30% Ethylene
Trace Amounts Heavies
Expander Type Centrifugal
Design Capacity (kg/hr) 549770
Adiabatic Efficiency 85
Power Output (kW) 4739
Description: 2nd Turbine Prepared By: MJH
Fluid Properties
58.04% Ethane
23.67% Nitrogen
6.30% Ethylene
Trace Amounts Heavies
Description: 3rd Turbine Prepared By: MJH
Fluid Properties
55.50% Ethane
Vapor Composition (mol%) 25.20% Nitrogen
12.77% Hydrogen
6.54% Ethylene
Description: 4th Turbine Prepared By: MJH
Fluid Properties
17.27% Ethane
56.84% Nitrogen
12.15% Ethylene
Inlet Pressure (kPa) 3000
Fluid Properties
9.68% Ethane
51.14% Nitrogen
13.26% Ethylene
Fluid Properties
4.28% Ethane
54.93% Nitrogen
12.96% Ethylene
Fluid Properties
2.80% Ethane
58.67% Nitrogen
8.80% Ethylene
Fluid Properties
1.59% Ethane
61.83% Nitrogen
5.25% Ethylene
Fluid Properties
0.74% Ethane
64.17% Nitrogen
2.58% Ethylene
Fluid Properties
0.26% Ethane
65.55% Nitrogen
0.97% Ethylene
A.7: Distillation Specifications (1 of 8)
Distillation Specifications
ID Number: T-300 Date: 5/11/2006
Description: Toluene/Ethylbenzene Distillation Column Prepared By: MSB
No. Required 1 Checked By: ACJ
Function
Feed Fluid
Feed Distillate Bottoms
Flow Rate (kg/hr) 236400 7924 228500
Vapor Fraction 0 1 0
Composition (mol fraction)

Methane 0.0000 0.0000 0.0000
Ethane 0.0000 0.0000 0.0000
n-Hexane 0.0005 0.0128 0.0000
1M3-EBenzene 0.0002 0.0000 0.0002
Toluene 0.0223 0.4947 0.0020
Benzene 0.0202 0.4913 0.0000
E-Benzene 0.4808 0.0012 0.5014
Hydrogen 0.0000 0.0000 0.0000
Oxygen 0.0000 0.0000 0.0000
Nitrogen 0.0000 0.0000 0.0000
H2O 0.0000 0.0000 0.0000
Ethylene 0.0000 0.0000 0.0000
Styrene 0.4754 0.0000 0.4958
n-Bbenzene 0.0000 0.0000 0.0000
Cumene 0.0002 0.0000 0.0003
n-Pbenzene 0.0000 0.0000 0.0000
AMS 0.0002 0.0000 0.0003
m-DiEBenzene 0.0001 0.0000 0.0001
CO2 0.0000 0.0000 0.0000
Carbon 0.0000 0.0000 0.0000
Temperature (C) 40 59.08 95.54

Pressure (kPa) 26.66 26.66 26.66
Number of Trays 66 Flood Vapor Velocity (ft/s) 3.878
Tray Spacing (in.) 24 Design Vapor Vel. (ft/s) 3.856
Feed Tray 50
Reflux Ratio 12 Height of Packing (m) 11.58
Pressure Drop (kPa) 3.3
Tray Efficiency 0.95
Tower Construction
Tray Type Flexipac HC
Tower Diameter (m) 2.12
Tower Height (m) 40.23
Design Temperature (C) 95.54
Design Pressure (kPa) 26.66
Description: Benzene/Toluene Distillation Column Prepared By: MSB
Function
Feed Fluid
Flow Rate (kg/hr) 7924 3673 4252

Methane 0.0000 0.0000 0.0000
Ethane 0.0000 0.0000 0.0000
n-Hexane 0.0128 0.0254 0.0000
1M3-EBenzene 0.0000 0.0000 0.0000
Toluene 0.4947 0.0001 0.9975
Benzene 0.4913 0.9745 0.0001
E-Benzene 0.0012 0.0000 0.0024
Hydrogen 0.0000 0.0000 0.0000
Oxygen 0.0000 0.0000 0.0000
Nitrogen 0.0000 0.0000 0.0000
H2O 0.0000 0.0000 0.0000
Ethylene 0.0000 0.0000 0.0000
Styrene 0.0000 0.0000 0.0000
n-Bbenzene 0.0000 0.0000 0.0000
Cumene 0.0000 0.0000 0.0000
n-Pbenzene 0.0000 0.0000 0.0000
AMS 0.0000 0.0000 0.0000
m-DiEBenzene 0.0000 0.0000 0.0000
CO2 0.0000 0.0000 0.0000
Carbon 0.0000 0.0000 0.0000
Temperature (C) 59.08 41.54 69.54

Pressure (kPa) 26.66 26.66 26.66
Feed Tray 10
Reflux Ratio 3.41
Tower Construction
Tray Type Sieve Tray
Description: Ethylbenzene/Styrene Distillation Column Prepared By: MSB
Function
Feed Fluid
Flow Rate (kg/hr) 228500 116100 112400

Methane 0.0000 0.0000 0.0000
Ethane 0.0000 0.0000 0.0000
n-Hexane 0.0000 0.0000 0.0000
1M3-EBenzene 0.0002 0.0000 0.0005
Toluene 0.0020 0.0041 0.0000
Benzene 0.0000 0.0000 0.0000
E-Benzene 0.5014 0.9957 0.0001
Hydrogen 0.0000 0.0000 0.0000
Oxygen 0.0000 0.0000 0.0000
Nitrogen 0.0000 0.0000 0.0000
H2O 0.0000 0.0000 0.0000
Ethylene 0.0000 0.0000 0.0000
Styrene 0.4958 0.0002 0.9982
n-Bbenzene 0.0000 0.0000 0.0000
Cumene 0.0003 0.0000 0.0005
n-Pbenzene 0.0000 0.0000 0.0000
AMS 0.0003 0.0000 0.0005
m-DiEBenzene 0.0001 0.0000 0.0002
CO2 0.0000 0.0000 0.0000
Carbon 0.0000 0.0000 0.0000
Temperature (C) 95.54 61.68 69.77

Pressure (kPa) 26.66 8.00 8.00
Feed Tray 48
Tower Construction
Description: Styrene/Heavies Distillation Column Prepared By: MSB
Function
Feed Fluid
Flow Rate (kg/hr) 112400 78580 33840

Methane 0.0000 0.0000 0.0000
Ethane 0.0000 0.0000 0.0000
n-Hexane 0.0000 0.0000 0.0000
1M3-EBenzene 0.0005 0.0001 0.0013
Toluene 0.0000 0.0000 0.0000
Benzene 0.0000 0.0000 0.0000
E-Benzene 0.0001 0.0001 0.0000
Hydrogen 0.0000 0.0000 0.0000
Oxygen 0.0000 0.0000 0.0000
Nitrogen 0.0000 0.0000 0.0000
H2O 0.0000 0.0000 0.0000
Ethylene 0.0000 0.0000 0.0000
Styrene 0.9982 0.9994 0.9954
n-Bbenzene 0.0000 0.0000 0.0000
Cumene 0.0005 0.0003 0.0010
n-Pbenzene 0.0000 0.0000 0.0000
AMS 0.0005 0.0000 0.0016
m-DiEBenzene 0.0002 0.0000 0.0007
CO2 0.0000 0.0000 0.0000
Carbon 0.0000 0.0000 0.0000
Temperature (C) 69.77 60.6 60.65

Pressure (kPa) 8.00 5.33 5.33
Feed Tray 24
Reflux Ratio 0.76 Height of Packing (m) 19.51
Pressure Drop (Psi.) 2.25
Tower Construction
Function
Feed Fluid
Flow Rate (kg/hr) 33840 26940 6893

Methane 0.0000 0.0000 0.0000
Ethane 0.0000 0.0000 0.0000
n-Hexane 0.0000 0.0000 0.0000
1M3-EBenzene 0.0013 0.0001 0.0058
Toluene 0.0000 0.0000 0.0000
Benzene 0.0000 0.0000 0.0000
E-Benzene 0.0000 0.0000 0.0000
Hydrogen 0.0000 0.0000 0.0000
Oxygen 0.0000 0.0000 0.0000
Nitrogen 0.0000 0.0000 0.0000
H2O 0.0000 0.0000 0.0000
Ethylene 0.0000 0.0000 0.0000
Styrene 0.9954 0.9994 0.9798
n-Bbenzene 0.0000 0.0000 0.0000
Cumene 0.0010 0.0005 0.0028
n-Pbenzene 0.0000 0.0000 0.0000
AMS 0.0016 0.0000 0.0078
m-DiEBenzene 0.0007 0.0000 0.0037
CO2 0.0000 0.0000 0.0000
Carbon 0.0000 0.0000 0.0000
Temperature (C) 60.65 60.61 60.82

Pressure (kPa) 5.33 5.33 5.33
Feed Tray 16
Reflux Ratio 1.29 Height of Packing (m) 19.51
Tower Construction
Function
Feed Fluid
Flow Rate (kg/hr) 6893 6715 178

Methane 0.0000 0.0000 0.0000
Ethane 0.0000 0.0000 0.0000
n-Hexane 0.0000 0.0000 0.0000
1M3-EBenzene 0.0058 0.0000 0.2572
Toluene 0.0000 0.0000 0.0000
Benzene 0.0000 0.0000 0.0000
E-Benzene 0.0000 0.0000 0.0000
Hydrogen 0.0000 0.0000 0.0000
Oxygen 0.0000 0.0000 0.0000
Nitrogen 0.0000 0.0000 0.0000
H2O 0.0000 0.0000 0.0000
Ethylene 0.0000 0.0000 0.0000
Styrene 0.9798 0.9994 0.1312
n-Bbenzene 0.0000 0.0000 0.0004
Cumene 0.0028 0.0006 0.1000
n-Pbenzene 0.0000 0.0000 0.0000
AMS 0.0078 0.0000 0.3480
m-DiEBenzene 0.0037 0.0000 0.1632
CO2 0.0000 0.0000 0.0000
Carbon 0.0000 0.0000 0.0000
Temperature (C) 60.82 60.6 73.3

Pressure (kPa) 5.33 5.33 5.33
Feed Tray 16
Tower Construction
Description: n-Hexane/Benzene Distillation Column Prepared By: MSB
Function
Feed Fluid
Flow Rate (kg/hr) 3673 366.2 3307

Methane 0.0000 0.0000 0.0000
Ethane 0.0000 0.0000 0.0000
n-Hexane 0.0254 0.2480 0.0014
1M3-EBenzene 0.0000 0.0000 0.0000
Toluene 0.0001 0.0000 0.0001
Benzene 0.9745 0.7520 0.9985
E-Benzene 0.0000 0.0000 0.0000
Hydrogen 0.0000 0.0000 0.0000
Oxygen 0.0000 0.0000 0.0000
Nitrogen 0.0000 0.0000 0.0000
H2O 0.0000 0.0000 0.0000
Ethylene 0.0000 0.0000 0.0000
Styrene 0.0000 0.0000 0.0000
n-Bbenzene 0.0000 0.0000 0.0000
Cumene 0.0000 0.0000 0.0000
n-Pbenzene 0.0000 0.0000 0.0000
AMS 0.0000 0.0000 0.0000
m-DiEBenzene 0.0000 0.0000 0.0000
CO2 0.0000 0.0000 0.0000
Carbon 0.0000 0.0000 0.0000
Temperature (C) 41.51 38.27 41.82

Pressure (kPa) 26.66 26.66 26.66
Feed Tray 28
Reflux Ratio 15
Pressure Drop (Psi.) 2
Tower Construction
Description: Ethylbenzene Recovery Prepared By: MSB
Function
Feed Fluid
Feed 1 Feed 2 Distillate Bottoms
Flow Rate (kg/hr) 111800 50190 124100 37920
Vapor Fraction 0 0.0459 1 0

Methane 0.0000 0.0000 0.0000 0.0000
Ethane 0.0000 0.0000 0.0000 0.0000
n-Hexane 0.0000 0.0004 0.0001 0.0000
1M3-EBenzene 0.0005 0.0000 0.0004 0.0000
Toluene 0.0000 0.0002 0.0001 0.0000
Benzene 0.0000 0.0000 0.0000 0.0000
E-Benzene 0.8299 0.7444 0.9982 0.0000
Hydrogen 0.0000 0.0000 0.0000 0.0000
Oxygen 0.0000 0.0000 0.0000 0.0000
Nitrogen 0.0000 0.0000 0.0000 0.0000
H2O 0.0000 0.0000 0.0000 0.0000
Ethylene 0.0000 0.0000 0.0000 0.0000
Styrene 0.0000 0.0000 0.0000 0.0000
n-Bbenzene 0.0094 0.0207 0.0000 0.0660
Cumene 0.0011 0.0000 0.0009 0.0000
n-Pbenzene 0.0000 0.0000 0.0000 0.0000
AMS 0.0000 0.0000 0.0000 0.0000
m-DiEBenzene 0.1591 0.2343 0.0002 0.9340
CO2 0.0000 0.0000 0.0000 0.0000
Carbon 0.0000 0.0000 0.0000 0.0000
Temperature (C) 152.50 155.6 147.5 193.9

Pressure (kPa) 135.9 135.8 135.8 135.8
Number of Trays 49 Flood Vapor Vel. (ft/s) 4.793
Feed Tray 12
Reflux Ratio 3
Tower Construction
A.8: Reactor Specifications (1 of 4)
Reactor Specifications
ID Number: R-100 Date: 5/8/2006
Description: Dehydrogenation Reactor Prepared By: MJH
No. Required 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
Design Data
Type Fluidized Catyst Cracking
Position Vertical
Volume (m3) 440.9
Tube Diameter (m) 3.8
Tube Length (m) 38.3
Description: Catalyst Regenerator Prepared By: MJH
Inlet Flows
Hydrogen (18.1 mol%), Oxygen (9.7%), Nitrogen (72.0%)
Vapor Feed 11408 kgmol/hr Trace: Ethane, Ethylene, Carbon
Outlet Flows
Nitrogen (79.2 mol%), Water (20.4%)
Inlet Exit
Design Data
Type Regenerator
Position Vertical
Volume (m3) 220.4
Description: Alkylation Reactor Prepared By: MJH
Inlet Flows
Ethane (83.5 mol%), Benzene (7.6%), Ethylene (8.9%)
Vapor Feed 31144 kgmol/hr Trace: n-Hexane, Toluene, Ethylbenzene, Nitrogen
Outlet Flows
Ethane (99.99 mol%)
Vapor Effluent 11060 kgmol/hr Trace: n-Hexane, Nitrogen, Ethylene
Ethylbenzene (79.4 mol%), Diethylbenzene (19.3%)

Liquid Effluent 1008 kgmol/hr n-Butylbenzene (1.1%)
Trace: Cumene, Polyalkylates, Styrene
Inlet Exit
Design Data
Type Distillation Reactor
Position Vertical
Volume (m3) 124
3
Void Volume (m ) 0.7
Packed Volume (m3) 0.3
Packed Diameter (m) 1.9
Packed Length (m) 6.5
Description: Transalkylator Prepared By: MJH
Inlet Flows
Diethylbenzene (93.4 mol%), n-Butylbenzene (6.6%)
Liquid Feed 441 kgmol/hr 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
Design Data
Type Packed Bed
Position Vertical
Volume (m3) 17
Void Volume (m3) 0.75
Packed Volume (m3) 0.25
Appendix B: PFD / PID / Layout
B.1 PFD: Alkylation Unit Area 100
114/ Ethylbenzene and Ethane

108
202 To Dehydrogenation
110
113/ Byproducts
Ethylene and Ethane 105/ 324 To Separations
From L.G. Separations 452 119
E-100
118
1
106
116
12 112
R-100 49 111
R-101
T-100
109
Benzene 104/ 117

From Separations 327
115
102
101 103
100
Benzene Feed
P-100
B.2 PFD: Dehydrogenation Unit Area 200
Hydrogen and Nitrogen 213/
From L.G. Separations 455
216 217
E-207
208 209
E-208
Air Feed K-201
230
215
218
210 214
R-200
E-206
R-
201
207
219
212
E-201
206
E-203
231
K-200 211
236/ Light Gas
K-200 401 To L.G.Separations
PFD pg. 6
205
232 233 234 V-202
E-204 E-205
235/ Products
E-200 301 To Separations
PFD pg. 6
204
K-202 221
Ethylbenzene 203/ 226
316
V-201
From Separations K-202
Water treatment
225 V-200 223 222

Ethylbenzene and Ethane 114/
220
From Alkylation 202
E-202
200 201 224
Ethane Feed 227 Purge

B.3 PFD: Separations Unit Area 300a inerts
inerts 311
Incinerated
T-302
Steam
308
Benzene
327
To Alkylation
Light Gases 312
Vented inerts
306
P-302
T-301
Steam
Toluene For
310
309 Sale
307
P-301
Products 235/
From Dehydrogenation 301
303 304 305
T-300
Steam
E-300
inerts
Products 453/
313
203/ Ethylbenzene
314
K-303
T-303
Steam
Styrene Finish
315
To Separations pg. 2
B.4 PFD: Separations Unit Area 300b
inerts
329
317 325 328
Styrene
E-301 P-303
E-302 to Customer
inerts
and Storage
P-1017
FC 319
inerts
321
Styrene Finish 315

From Separations pg. 1 T-304 P-1018
Steam
318
T-305
P-1019
Steam
320 T-306
Steam
322
Byproducts 113/ Heavy Byproducts

323
From Alkylation 324 To Treatment
B.5 PFD: Light Gas SeparationsArea 400
Light Gas 236/

401
402 403 404 V-400 405 406 407 408 V-401 409 411 412 413 V-402
From Dehydrogenation
K-400 E-400 M-400 K-401 E-401 M-401 K-402 E-402 M-402
PFD pg. 6 PFD pg. 6

410 414
415 416 417 418 V-403 420 421 422 423 V-404 425 426 427 428 V-405
K-403 E-403 M-403 K-404 E-404 M-404 K-405 E-405 M-405
PFD pg. 6 PFD pg. 6 PFD pg. 6
419 424 429
430 431 432 433 V-406 435 436 437 438 V-407 440 441 442 443 V-408
K-406 E-406 M-406 K-407 E-407 M-407 K-408 E-408 M-408
PFD pg. 6 PFD pg. 6 PFD pg. 6
434 439 444
213/ Hydrogen and Nitrogen

445 446 447 448 V-409 450 451 454
K-409 E-409 M-409 K-410 E-410
PFD pg. 6 456
449
To Treatment
105/ Ethylene and Ethane

452 To Alkylation
453/ Products
302 To Separations
B.6 PFD: PFD pg. 6 Compressor Chains
Dehydrogenation L.G. Separations
K-200 K-403
205. 205. 205. 415. 415. 415. 415.

205 206 415 416
1 2 3 1 2 3 4
K-200.1 K-200.2 K-200.3 E-200.1 K-403.1 E-403.1 K-403.2 E-403.2 K-403.3

K-202 K-404
221. 221. 221. 420. 420. 420. 420.

221 222 420 421
1 2 3 1 2 3 4
K-202.1 E-202.1 K-202.2 E-202.2 K-404.1 E-404.1 K-404.2 E-404.2 K-404.3
L.G. Separations L.G. Separations

K-401 K-405
405. 405. 405. 405. 425. 425. 425. 425.

405 425 426
1 2 3 4 1 2 3 4
K-401.1 E-401.1 K-401.2 E-401.2 K-405.1 E-405.1 K-405.2 E-405.2 K-405.3
405. 405. 405. 405.

5 6 7 8
L.G. Separations
K-406
K-401.3 E-401.3 K-401.4 E-401.4
430. 430. 430. 430.

430 431
1 2 3 4
405. 405.
406 K-406.1 E-406.1 K-406.2 E-406.2 K-406.3
9 10
K-401.5 E-401.5 K-401.6
L.G. Separations
K-407
L.G. Separations
K-402
435. 435. 435. 435.
435 436
1 2 3 4
409. 409. 409. 409.
409 K-407.1 E-407.1 K-407.2 E-407.2 K-407.3
1 2 3 4
K-402.1 E-402.1 K-402.2 E-402.2
L.G. Separations
409. 409. 409. 409. K-408
5 6 7 8
K-402.3 E-402.3 K-402.4 E-402.4 440. 440. 440. 440.

440 441
1 2 3 4
K-408.1 E-408.1 K-408.2 E-408.2 E-408.3

411
402.5
L.G. Separations
K-409
445. 445. 445. 445.

445 446
1 2 3 4
K-409.1 E-250 E-251 E-248 E-252

B.7 P&ID: Alkylation Unit Area 100
FC
114/ Ethylbenzene and Ethane
108
110
LC
V-93
113/ Byproducts
Ethylene and Ethane 105/ 324 To Separations
From L.G. Separations 452 119
E-100
118
1
106
116
12 112
FC
R-100 49 111
R-101
T-100
LC
109
Benzene 104/ 117

From Separations 327
115
FC
102
101 103
100
Benzene Feed FC
P-100
B.8 P&ID: Dehydrogenation Unit Area 200
Hydrogen and Nitrogen 213/
TC TC
FC PC
216 217
E-207
208 209
E-208
Air Feed K-201
230
215
218
210 214 TC
R-200
E-206
R-
201
207
FC
219
212
E-201
206
TC E-203
231
K-200 211
236/ Light Gas
K-200 401
TC
To L.G.Separations
P&ID pg. 6 TC
205
E-204
232 233 234
E-205
TC E-200 226
235/ Products
301 To Separations
P&ID pg. 6
204
K-202 221
Ethylbenzene 203/
FC
From Separations 316 K-202
Water treatment
E-202
225 223 222

Ethylbenzene and Ethane 114/
220
From Alkylation 202
TC
FC
200 201 224
Ethane Feed
227 Purge
B.9 P&ID: Separations Unit Area 300a inerts
LC
PC
inerts 311
FC Incinerated
T-302
TC FC
Steam
308
LC
LC
PC Benzene
327
To Alkylation
Light Gases 312
Vented inerts FC
306
P-302
T-301
TC FC
Steam
LC
LC
Toluene For
310
PC Sale
309
307
FC
FC P-301
Products 235/
303 304 305
T-300
TC FC Steam
E-300
inerts
Products 453/ LC
LC
313
PC
203/ Ethylbenzene
314
FC
K-303
T-303
TC
FC
Steam
LC
Styrene Finish
315
To Separations pg. 2
B.10 P&ID: Separations Unit Area 300b
inerts
FC
329
317 325 326 328
E-301 E-181
E-101
inerts
LC
PC FC 319
inerts
321
Styrene Finish 315 TC

From Separations pg. 1 T-304 LC
FC
PC
Steam
FC
LC 318
T-305 TC LC
FC
PC
Steam
FC
LC 320 T-306 TC
FC
Steam
LC
322
Byproducts 113/ Heavy Byproducts

323
From Alkylation 324 To Treatment
B.11 P&ID: Light Gas SeparationsArea 400
Light Gas 236/

402 403 404 405 406 407 408 409 411 412 413
K-400 E-400 M-400 K-401 E-401 M-401 K-402 E-402 M-402
V-400 P&ID pg. 6 V-401 P&ID pg. 6 V-402
410 414
415 416 417 418 420 421 422 423 425 426 427 428
K-403 E-403 M-403 K-404 E-404 M-404 K-405 E-405 M-405
P&ID pg. 6 V-403 P&ID pg. 6 V-404 P&ID pg. 6 V-405
419 424 429
430 431 432 433 435 436 437 438 440 441 442 443
K-406 E-406 M-406 K-407 E-407 M-407 K-408 E-408 M-408
P&ID pg. 6 V-406 P&ID pg. 6 V-407 P&ID pg. 6 V-408
434 439 444
213/ Hydrogen and Nitrogen

445 446 447 448 450 451 454
K-409 E-409 M-409 K-410 E-410
P&ID pg. 6 V-409 456
449
To Treatment
105/ Ethylene and Ethane

452 To Alkylation
453/ Products
302 To Separations
B.12 P&ID: P&ID pg. 6 Compressor Chains
Dehydrogenation L.G. Separations Controls for each Compressor and
K-200 K-403 Heat Exchanger in the Process F
205. 205. 205. 415. 415. 415. 415.

205 206 415 416
1 2 3 1 2 3 4
FC
K-200.1 K-200.2 K-200.3 K-403.1 E-403.1 K-403.2 E-403.2 K-403.3 PC
E-200.1
TC

K-202 K-404
221. 221. 221. 420. 420. 420. 420.

221 222 420 421
1 2 3 1 2 3 4
K-202.1 E-202.1 K-202.2 E-202.2 K-404.1 E-404.1 K-404.2 E-404.2 K-404.3
L.G. Separations L.G. Separations

K-401 K-405
405. 405. 405. 405. 425. 425. 425. 425.

405 425 426
1 2 3 4 1 2 3 4
K-401.1 E-401.1 K-401.2 E-401.2 K-405.1 E-405.1 K-405.2 E-405.2 K-405.3
405. 405. 405. 405.

5 6 7 8
L.G. Separations
K-406
K-401.3 E-401.3 K-401.4 E-401.4
430. 430. 430. 430.

430 431
1 2 3 4
405. 405.
406 K-406.1 E-406.1 K-406.2 E-406.2 K-406.3
9 10
K-401.5 E-401.5 K-401.6
L.G. Separations
K-407
L.G. Separations
K-402
435. 435. 435. 435.
435 436
1 2 3 4
409. 409. 409. 409.
409 K-407.1 E-407.1 K-407.2 E-407.2 K-407.3
1 2 3 4
K-402.1 E-402.1 K-402.2 E-402.2
L.G. Separations
409. 409. 409. 409. K-408
5 6 7 8
K-402.3 E-402.3 K-402.4 E-402.4 440. 440. 440. 440.

440 441
1 2 3 4
K-408.1 E-408.1 K-408.2 E-408.2 E-408.3

411
402.5
L.G. Separations
K-409
445. 445. 445. 445.

445 446
1 2 3 4
K-409.1 E-250 E-251 E-248 E-252

AREA 300 --
B.13: Plant Layout SEPARATIONS
5.63m.
3.59m.
3.80m. 3.80m. T-303
T-305
Dehydrogenation
Dehydro Dehydrogenation
2.12m.
T-300
0.80m.
T-301 3.64m.
3.80m. 3.80m.
5.61m. T-306
0.34m.
T-
Dehydrogenation Dehydrogenation
30 T-304
2
AREA 200 --
DEHYDROGENATION
1.90m. 1.90m. 1.90m. 1.90m.
V-407 V-408 V-409

V-400
Alkylator Alkylator Alkylator Alkylator
V-406
V-405 V-404
3.55m.
V-401 Alkylation Tower AREA 100 --

V-403
V-402 ALKYLATION
Trans Trans Trans Trans

Akylator Akylator Akylator Akylator
AREA 400
LIGHT GASES SEPARATION 1.10m. 1.10m. 1.10m. 1.10m.
FRONT
B.14: Plant Layout, Front View
10.00m.
10.00m.
10.00m.
T-300
Dehydro Dehydro
Tr Tr Tr Tr
a a a a
n n n n
s s s s
10.00m.
Al Al Alkylation
Al Al
k k Tower k k
yl yl
T-304 yl yl
T
at at at at
-
or or or or
3
0
2Alkyl Alkyl Alkyl Alkyl
ator ator ator ator
T-306
T
-
3
0
10.00m.
1
V-400 V-402
V-401
V- V- V- V-
V- V- V-
40 4040 403
40 40 40
6 7 5 8 4 9
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
3
atm ft
P := 0.2631 atm R := 1.314 lbmol K T := 368.69 K
lb lb
MWv := 85.187 MWl := 105.15 3
lbmol lbmol v := 7.3254 10 cP
lbmol lbmol dyne

L := 4791 V := 205.1 := 21.913
hr hr cm
2 lb lb
v := 5.1336 10 l := 51.077 NumberOfTrays := 66
3 3
ft ft
Wl := L MWl
Wv := V MWv
Wl
= 28.833
Wv
0.5
Wl v
Flv :=
Wv l
Flv = 0.914
From Wankat equation 12-10e for 24-in tray spacing
2
logCsb := .94506 0.70234 log( Flv) 0.22618 ( log ( Flv) )
Finding Csb:
logCsb
Csb := 10
Csb = 0.121
0.2
K := Csb

20
K = 0.123
v = 0.051
l = 51.077
0.5
l v
uflood := K
v
uflood = 3.878
fraction := 0.75
uop := ( fraction ) uflood
uop = 2.909
Finding the Diameter using equation 12-14 Wankat

:= 0.95
0.5
( 4 V MWv)
Dia := ( )
v fraction uflood 3600
Dia = 6.6 ft
Diameter := Dia
30.48

100
Diameter = 2.012 m
Calculations for Column Diameter in Separations Unit : Tray Column T-300 Middle of Column
3
atm ft
P := 0.2631 atm R := 1.314 lbmol K T := 363.45 K
lb lb
MWv := 85.187 MWl := 105.15 3
lbmol lbmol dyne

L := 4791 V := 205.1 := 21.913
hr hr cm
2 lb lb
3 3
ft ft
Wl := L MWl
Wv := V MWv
Wl
= 28.833
Wv
0.5
Wl v
Flv := Wv
l
Flv = 0.914
2
Finding Csb:
logCsb
Csb := 10
Csb = 0.121
0.2
K := Csb

20
K = 0.123
v = 0.051
l = 51.077
0.5
uflood := K
l v

v
uflood = 3.878
fraction := 0.75
uop = 2.909

:= 0.95
0.5
( 4 V MWv)
Dia := ( )
Dia = 6.6 ft
Diameter := Dia
30.48

100
Diameter = 2.012 m
Calculations for Column Diameter in Separations Unit : Tray Column T-300 Top of Column
3
atm ft
P := 0.2631 atm R := 1.314 lbmol K T := 332.23 K
lb lb
MWv := 85.187 MWl := 105.15 3
lbmol lbmol dyne

L := 4791 V := 205.1 := 21.913
hr hr cm
2 lb lb
3 3
ft ft
Wl := L MWl
Wv := V MWv
Wl
= 28.833
Wv
0.5
Wl v
Flv :=
Wv l
Flv = 0.914
2
Finding Csb:
logCsb
Csb := 10
Csb = 0.121
0.2
K := Csb

20
K = 0.123
v = 0.051
l = 51.077
0.5
uflood := K
l v

v
uflood = 3.878
fraction := 0.75
uop = 2.909

:= 0.95
0.5
( 4 V MWv)
Dia := ( )
Dia = 6.6 ft
Diameter := Dia
30.48

100
Diameter = 2.012 m
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 bar Pressure 0.267 bar

1.0133 bar/atm 1.013 bar/atm
0.2631 atm 0.263 atm
deg Celsius K deg Celsius K
Top 59.08 332.23 Top 38.27 311.42
Middle 90.3 363.45 Middle 41.51 314.66
Bottom 95.54 368.69 Bottom 41.82 314.97
Average 81.64 354.79 Average 40.53 313.68
Tray Spacing 24 in. Tray Spacing 24 in.
Number of Trays 66 Number of Trays 40
Column Height 1584 in. 132 ft Column Height 960 in. 80.00 ft
39.37 in./m 39.37 in./m
40.23 m 24.38 m
Column Diameter Column Diameter
Top 2.12 m 6.96 ft Top 0.34 m 1.10 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
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

0.2631 atm 0.079 atm
Top 41.51 314.66 Top 61.68 334.83
Middle 58.17 331.32 Middle 62.42 335.57
Bottom 69.54 342.69 Bottom 69.77 342.92
Average 56.41 329.56 Average 64.62 337.77
Number of Trays 23 46.00 ft Number of Trays 72
Column Height 552 in. Column Height 1728 in. 144 ft
39.37 in./m 39.37 in./m
14.02 m 43.89 m
Top 0.80 m 0.00 ft Top 5.63 m 18.47 ft

Column diameter range is from 7.5-over 29ft or 2.3-~9m
Styrene Finish
T-304 T-306

0.053 atm 0.053 atm
Top 60.6 333.75 Top 60.6 333.75
Middle 60.61 333.76 Middle 60.69 333.84
Bottom 60.65 333.8 Bottom 73.3 346.45
Average 60.62 333.77 Average 64.86 338.01
Number of Trays 45 Number of Trays 30
Column Height 1080 in. 90.00 ft Column Height 720 in. 60.00 ft
39.37 in./m 39.37 in./m
27.43 m 18.29 m
Top 5.61 m 18.41 ft 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
According to vendor information KOCH-GLITSCH According to vendor information KOCH-GLITSCH

Column diameter range is from 7-17.5ft or 2.1-~5.3m Column diameter range is from 7-17.5ft or 2.1-~5.3m
T-305
Pressure 0.053 bar

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

Column diameter range is from 7-17.5ft or 2.1-~5.3m
Alkylation Unit
T-101
Pressure 1.358 bar

1.013 bar/atm
1.340 atm
deg Celsius K
Top 147.5 420.65
Middle 193.8 466.95
Bottom 193.9 467.05
Average Temp 178.4 451.55
Tray Spacing 24 in.
Number of Trays 49
Column Height 1176 in. 98.00 ft
39.37 in./m
29.87 m
Column Diameter
Top 3.55 m 11.65 ft
C.3: Fenske Equation (1 of 3)
Hand Calculations for Minimum Reflux using Fenske's equation
Mix 3 going into separations B-100 Ethylbenzene/Styrene Split

By Products MW Bp K alpha Mol fraction By Products MW Bp K alpha Mol fraction
Hydrogen 2.02 -252.6 8.72E+03 0.0000 Hydrogen 2.02 -252.6 8.72E+03 0.0000
Nitrogen 28.01 -195.8 4.31E+03 2.02 0.0000 Nitrogen 28.01 -195.8 4.31E+03 2.02 0.0000
Ethylene 28.05 -103.75 3.11E+02 13.84 0.0000 Ethylene 28.05 -103.75 3.11E+02 13.84 0.0000
Ethane 30.07 -88.6 2.46E+02 1.27 0.0000 Ethane 30.07 -88.6 2.46E+02 1.27 0.0000
n-Hexane 86.18 68.73 1.18E+00 207.78 0.0005 n-Hexane 86.18 68.73 1.18E+00 207.78 0.0000
Benzene 78.11 80.09 7.85E-01 1.51 0.0200 Benzene 78.11 80.09 7.85E-01 1.51 0.0000
Toluene 92.14 110.65 2.70E-01 2.91 0.0223 Toluene 92.14 110.65 2.70E-01 2.91 0.0021
Ethylbenzene 106.17 136.2 1.01E-01 2.67 0.4821 Ethylbenzene 106.17 136.2 1.01E-01 2.67 0.5025
Styrene 104.15 145.16 6.86E-02 1.47 0.4744 Styrene 104.15 145.16 6.86E-02 1.47 0.4945
cumene 120.19 152.41 4.39E-02 1.56 0.0002 cumene 120.19 152.41 4.39E-02 1.56 0.0002
n-p-benzene 120.19 159.24 8.49E-03 5.17 0.0000 n-p-benzene 120.19 159.24 8.49E-03 5.17 0.0000
1M3-EBenzene 120.19 161.33 3.52E-02 0.24 0.0002 1M3-EBenzene 120.19 161.33 3.52E-02 0.24 0.0002
-methylstyrene 118.18 165.5 2.70E-02 1.31 0.0002 -methylstyrene 118.18 165.5 2.70E-02 1.31 0.0002
m-DiEBenzene 134.22 181.14 1.30E-02 2.07 0.0001 m-DiEBenzene 134.22 181.14 1.30E-02 2.07 0.0001
n-Butyl-Benzene 134.22 183.3 9.95E-03 1.31 0.0000 n-Butyl-Benzene 134.22 183.3 9.95E-03 1.31 0.0000
All taken from HYSYS
The closer to 1 the harder to separate Vent Gas Distillate
Distillate Bottoms
T-300 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 19 Nmin 20
FRC,dist 0.9999 FRC,dist 1.00
Styrene/Cumene Split Styrene/Cumene Split

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

Bottoms EBC 2.30 Bottoms
T-304 EBS 1.47
EBC 2.30 SS 1.00
EBS 1.47 CS 0.64
SS 1.00 zEB 0.000
CS 0.64 zC 0.001
zEB 0.000 zS 1.00
zC 0.001 FRA,dist 0.9993
zS 1.00 FRB,dist 0.9993
FRA,dist 0.9993 Nmin 32
FRB,dist 0.9993 FRC,dist 1.00
Nmin 32
FRC,dist 1.00
Styrene/Cumene Split
By Products MW Bp K alpha Mol fraction
Hydrogen 2.02 -252.6 8.72E+03 0.0000
Nitrogen 28.01 -195.8 4.31E+03 2.02 0.0000
Ethylene 28.05 -103.75 3.11E+02 13.84 0.0000
Ethane 30.07 -88.6 2.46E+02 1.27 0.0000
n-Hexane 86.18 68.73 1.18E+00 207.78 0.0000
Benzene 78.11 80.09 7.85E-01 1.51 0.0000
Toluene 92.14 110.65 2.70E-01 2.91 0.0000
Ethylbenzene 106.17 136.2 1.01E-01 2.67 0.0000
Styrene 104.15 145.16 6.86E-02 1.47 0.9800
cumene 120.19 152.41 4.39E-02 1.56 0.0028
n-p-benzene 120.19 159.24 8.49E-03 5.17 0.0005
1M3-EBenzene 120.19 161.33 3.52E-02 0.24 0.0057
-methylstyrene 118.18 165.5 2.70E-02 1.31 0.0078
m-DiEBenzene 134.22 181.14 1.30E-02 2.07 0.0000
n-Butyl-Benzene 134.22 183.3 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 28
FRC,dist 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 T-303
Molar Mass: Liquid Vapor Molar Mass: Liquid Vapor
Molar Mass (kg/kgmole) 105.15 85.19 Molar Mass (kg/kgmole) 104.18 106.11
Surface tension Surface tension

dyne/cm 21.913 dyne/cm 25.695
kg/s2 0.021913 kg/s2 0.025695
Viscosity Viscosity
cP 0.30367 0.007325 cP 0.41967 0.0063562
kg/m*s 3.04E-04 7.33E-06 kg/m*s 4.20E-04 6.3562E-06
Flows Flows
kmol/h 2421 102.8 kmol/h 1199 1222
kmol/s 0.6725 0.0286 kmol/s 0.3331 0.3394
T-304 T-305
Molar Mass: Liquid Vapor Molar Mass: Liquid Vapor
Molar Mass (kg/kgmole) 104.23 104.16 Molar Mass (kg/kgmole) 104.51 104.16
Surface tension Surface tension

dyne/cm 26.67 dyne/cm 26.619
kg/s2 0.02667 kg/s2 0.026619
Viscosity Viscosity
cP 0.46345 0.006295 cP 0.46407 0.0062951
kg/m*s 4.63E-04 6.30E-06 kg/m*s 4.64E-04 6.30E-06
Flows Flows
kmol/h 360.7 838.3 kmol/h 73.27 287.4
kmol/s 0.100194 0.23286 kmol/s 0.02035 0.07983
C.4: Dimensioning of Packed Columns (2 of 2)
T-306
Molar Mass: Liquid Vapor
Molar Mass (kg/kgmole) 119.68 104.16
Surface tension
dyne/cm 23.651
kg/s2 0.023651
Viscosity
cP 0.47297 0.006295
kg/m*s 4.73E-04 6.30E-06
Flows
kmol/h 1.634 71.64
kmol/s 0.000454 0.0199
C.5: Dimensioning a Packed Column
Taken from Fair, J. and Stichlmair, J. p. 457
Liquid Phase Gas Phase
kg
kg
Molar Mass Ml := 105.15 kmol
Mg := 85.19 kmol
kg
kg
Density l := 818.17 3
m g := 0.82233 3
m
kg
Surface Tension := 0.021913
2
s
4 kg
l := 3.04 10 6 kg
Viscosity m s g := 7.33 10
m s
kmol Liqflow := 0.6725 kmol
Gasflow := 0.0286
s s
Assumption of Operational gas flow rate:
0.5
Flow := 2.0 Pa
Flow
ug :=
(g0.5)
m
ug = 2.205 s
Mg
Vg := Gasflow
g
3
m
Vg = 2.963
s
Cross section Ac
Vg
Ac :=
ug
2
Ac = 1.343 m
0.5
Ac
Dc := 4

Dc = 1.308 m
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 Pressure(kPa) 26.66 Pressure(kPa) 26.66

Condenser Temp (deg C) 86.23 Condenser Temp (deg C) 82.23 Condenser Temp (deg C) 73.20
Reboiler Temp (deg C) 97.09 Reboiler Temp (deg C) 96.95 Reboiler Temp (deg C) 96.48
Comp Recovery of Toluene 0.9999 Comp Recovery of Toluene 0.9999 Comp Recovery of Toluene 0.9999
Reflux Ratio 3 Reflux Ratio 5 Reflux Ratio 10
Total Trays w/o C & R 67 Total Trays w/o C & R 67 Total Trays w/o C & R 67
Tray Position 50 Tray Position 50 Tray Position 50
Composition of Exiting streams Composition of Exiting streams Composition of Exiting streams
Chemicals Overhead exiting Bottoms Exiting Chemicals Overhead exiting Bottoms Exiting Chemicals Overhead exiting Bottoms Exiting
Methane 0.0000 0.0000 Methane 0.0000 0.0000 Methane 0.0000 0.0000
Ethane 0.0698 0.0000 Ethane 0.0931 0.0000 Ethane 0.1510 0.0000
n-Hexane 0.0022 0.0000 n-Hexane 0.0030 0.0000 n-Hexane 0.0049 0.0000
Ethyl Toluene(1M3-Ebenzene) 0.0000 0.0000 Ethyl Toluene(1M3-Ebenzene) 0.0000 0.0000 Ethyl Toluene(1M3-Ebenzene) 0.0000 0.0000
Toluene 0.1129 0.0000 Toluene 0.1508 0.0000 Toluene 0.2444 0.0000
Benzene 0.1118 0.0000 Benzene 0.1492 0.0000 Benzene 0.2419 0.0000
Ethyl Benzene 0.5757 0.3287 Ethyl Benzene 0.5909 0.3447 Ethyl Benzene 0.3429 0.3985
Hydrogen 0.0001 0.0000 Hydrogen 0.0001 0.0000 Hydrogen 0.0001 0.0000
Oxygen 0.0000 0.0000 Oxygen 0.0000 0.0000 Oxygen 0.0000 0.0000
Nitrogen 0.0023 0.0000 Nitrogen 0.0030 0.0000 Nitrogen 0.0049 0.0000
Water 0.0000 0.0000 Water 0.0000 0.0000 Water 0.0000 0.0000
Ethylene 0.0046 0.0000 Ethylene 0.0061 0.0000 Ethylene 0.0099 0.0000
Styrene 0.1207 0.6640 Styrene 0.0037 0.6486 Styrene 0.0000 0.5954
n-B-Benzene 0.0000 0.0000 n-B-Benzene 0.0000 0.0000 n-B-Benzene 0.0000 0.0000
Cumene 0.0000 0.0023 Cumene 0.0000 0.0021 Cumene 0.0000 0.0019
n-P-Benzene 0.0000 0.0026 n-P-Benzene 0.0000 0.0024 n-P-Benzene 0.0000 0.0022
AMS 0.0000 0.0023 AMS 0.0000 0.0021 AMS 0.0000 0.0019
Heating Duties Heating Duties Heating Duties

Condenser (kJ/h) 6.36911E+07 Condenser (kJ/h) 7.93204E+07 Condenser (kJ/h) 9.88086E+07
Reboiler (kJ/h) 1.04578E+08 Reboiler (kJ/h) 1.14809E+08 Reboiler (kJ/h) 1.28452E+08
Vessel Parameters Vessel Parameters Vessel Parameters

Vessel Reboiler Condenser Vessel Reboiler Condenser Vessel Reboiler Condenser
Diameter (m) 1.193 1.193 Diameter (m) 1.193 1.193 Diameter (m) 1.193 1.193
Height(m) 1.789 1.789 Height(m) 1.789 1.789 Height(m) 1.789 1.789
3
Volume(m ) 2.000 2.000 Volume(m3) 2.000 2.000 Volume(m3) 2.000 2.000
Liq Vol. (%) 50.000 50.000 Liq Vol. (%) 50.000 50.000 Liq Vol. (%) 50.000 50.000
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Vessel Delta P (kPa) 0.00 0.00 Vessel Delta P (kPa) 0.00 0.00 Vessel Delta P (kPa) 0.00 0.00
Fixed Vessel P Spec. (kPa) 26.66 26.66 Fixed Vessel P Spec. (kPa) 26.66 26.66 Fixed Vessel P Spec. (kPa) 26.66 26.66
Tray Section Tray Section Tray Section
Diameter (m) 1.500 Diameter (m) 1.500 Diameter (m) 1.500
Tray/Packed Space (m) 0.550 Tray/Packed Space (m) 0.550 Tray/Packed Space (m) 0.550
Tray/Packed Vol.(m3) 0.972 Tray/Packed Vol.(m3) 0.972 Tray/Packed Vol.(m3) 0.972
Hold up (m3) 0.088 Hold up (m3) 0.088 Hold up (m3) 0.088
C.7: Optimization Reflux Ratio (2of 6)
Figure 1A: Optimization of Reflux Ratio Figure1C: Optimization of Reflux Ratio

Comp Recovery of Toluene = 0.9999 Comp Recovery of Toluene =0.9999
1.2E+08
0.1400
Mole Fraction of Styrene in the overhead

1.0E+08 0.1200
Condenser Duty (kJ/h)
8.0E+07 0.1000
0.0800
6.0E+07
0.0600
4.0E+07
0.0400
2.0E+07
0.0200
0.0E+00 0.0000
3 5 10 15 0 2 4 6 8 10 12 14 16
Reflux Ratio Reflux Ratio
Figure 1B: Optimization of Reflux Ratio Figure1D: Optimization of Reflux Ratio

Comp Recovery of Toluene =0.9999 Comp Recovery of Toluene =0.9999
1.6E+08 0.6700
Mole Fraction of Styrene in the bottoms

0.6600
1.4E+08
0.6500
1.2E+08
Reboiler Duty (kJ/h)
0.6400
1.0E+08
0.6300
8.0E+07 0.6200
6.0E+07 0.6100
0.6000
4.0E+07
0.5900
2.0E+07
0.5800
0.0E+00
0.5700
3 5 10 15 0 2 4 6 8 10 12 14 16
Reflux Ratio Reflux Ratio
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


Comp Recovery of Ethylbenzene 0.9999 Comp Recovery of Ethylbenzene 0.9999 Comp Recovery of Ethylbenzene 0.9999
AMS 0.0000 0.0018 AMS 0.0000 0.0018 AMS 0.0000 0.0019


3
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Column 100 Figure 1A: Optimization of Reflux Ratio Figure 2A: Optimization of Reflux Ratio
Optimal Reflux Comp Recovery of Toluene = 0.9999 Comp Recovery of EB = 0.9999
Pressure(kPa) 26.66 1.20E+08 3.50E+08
Condenser Temp (deg C) 51.90
Reboiler Temp (deg C) 96.27 3.00E+08
Comp Recovery of Ethylbenzene 0.9999 1.00E+08
Reflux Ratio 12
2.50E+08
Total Trays w/o C & R 67

8.00E+07
Tray Position 50
Composition of Exiting streams 2.00E+08
Chemicals Overhead exiting Bottoms Exiting 6.00E+07
Methane 0.0000 0.0000 1.50E+08
Ethane 0.2298 0.0000
4.00E+07
n-Hexane 0.0074 0.0000
1.00E+08
Ethyl Toluene(1M3-Ebenzene) 0.0000 0.0000
Toluene 0.3715 0.0000 2.00E+07
Benzene 0.3681 0.0000 5.00E+07
Ethyl Benzene 0.0005 0.4248
Hydrogen 0.0002 0.0000 0.00E+00 0.00E+00
Oxygen 0.0000 0.0000 3 5 10 15 3 5 10 12 15 20 30 40 50
Nitrogen 0.0075 0.0000 Reflux Ratio Reflux Ratio
Water 0.0000 0.0000
Ethylene 0.0151 0.0000
Styrene 0.0000 0.5693
n-B-Benzene 0.0000 0.0000 Figure 2B: Optimization of Reflux Ratio Figure 2C: Optimization of Reflux Ratio
Cumene 0.0000 0.0019 Comp Recovery of EB =0.9999 Comp Recovery of EB =0.9999
n-P-Benzene 0.0000 0.0021 0.0000
AMS 0.0000 0.0019 60
Mole Fraction of Styrene in the overhead

Heating Duties 0.0000
50
Condenser (kJ/h) 7.21977E+07
Reboiler (kJ/h) 9.84124E+07
0.0000
Reboiler Duty (kJ/h)
40
Vessel Parameters
Vessel Reboiler Condenser 0.0000
30
Diameter (m) 1.193 1.193
Height(m) 1.789 1.789
3 0.0000
Volume(m ) 2.000 2.000 20
Liq Vol. (%) 50.000 50.000
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10 0.0000
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Vessel Delta P (kPa) 0.00 0.00
Fixed Vessel P Spec. (kPa) 26.66 26.66 0 0.0000
Tray Section 3 5 10 12 15 20 30 40 50 0 10 20 30 40 50 60
Diameter (m) 1.500 Reflux Ratio Reflux Ratio
Tray/Packed Space (m) 0.550
Tray/Packed Vol.(m3) 0.972
Hold up (m3) 0.088
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.

AMS 0.0000 0.0019 AMS 0.0000 0.0019 AMS 0.0000 0.0019


3
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OPTIMAL STAGE FROM SHORT-CUT DIST. IN HYSYS


AMS 0.0000 0.0019 AMS 0.0000 0.0019 AMS 0.0000 0.0019


Volume(m3) 2.000 2.000 Volume(m3) 2.000 2.000 Volume(m3) 2.000 2.000
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Appendix D: Compressor Optimization
D.1: Compressor Optimization Analysis
K-401 K-402 K-403
Compressors Total Cost/Year Compressors Total Cost/Year Compressors Total Cost/Year
1 $ 135,211,913.38 1 $ 83,109,284.25 1 $ 16,723,672.81
2 $ 46,301,845.84 2 $ 36,885,784.77 2 $ 13,259,425.74
3 $ 36,120,548.92 3 $ 31,026,285.60 3 $ 12,954,054.50
4 $ 34,700,489.93 4 $ 30,567,660.67 4 $ 12,974,991.53
5 $ 34,117,414.99 5 $ 30,323,544.51 5 $ 13,112,584.04
6 $ 34,019,360.00 6 $ 30,344,373.78 6 $ 13,270,201.88
7 $ 34,056,600.61 7 $ 30,474,470.36 7 $ 13,343,714.61
K-404 K-405 K-406

1 $ 14,393,491.14 1 $ 11,799,344.63 1 $ 11,552,286.13
2 $ 11,988,687.07 2 $ 10,330,926.05 2 $ 10,271,294.13
3 $ 11,738,395.62 3 $ 10,156,880.73 3 $ 10,070,266.22
4 $ 11,816,536.09 4 $ 10,263,640.47 4 $ 10,211,462.87
5 $ 11,976,656.42 5 $ 10,423,114.77 5 $ 10,394,355.66
6 $ 12,141,798.15 6 $ 10,534,134.01 6 $ 10,482,010.82
7 $ 12,181,480.61 7 $ 10,598,345.00 7 $ 10,562,234.00
K-407 K-408 K-409

1 $ 9,993,175.16 1 $ 9,442,799.04 1 $ 8,645,010.91
2 $ 9,272,843.40 2 $ 9,054,784.68 2 $ 8,584,023.83
3 $ 9,079,644.47 3 $ 8,820,671.40 3 $ 8,343,378.82
4 $ 9,266,368.96 4 $ 9,072,796.99 4 $ 8,654,569.23
5 $ 9,465,635.45 5 $ 9,210,912.53 5 $ 8,748,205.56
6 $ 9,515,501.58 6 $ 9,321,584.03 6 $ 8,897,823.72
7 $ 9,613,541.49 7 $ 9,418,821.32 7 $ 8,968,179.58
K-410 K-400 K-200

1 $ 442,471.46 1 $ 3,085,513.74 1 $ 11,254,434.85
2 $ 453,857.44 2 $ 3,284,760.49 2 $ 10,294,761.84
3 $ 454,264.96 3 $ 3,424,930.82 3 $ 10,194,445.14
4 $ 471,742.91 4 $ 3,742,178.44 4 $ 10,546,200.01
5 $ 10,949,864.13
K-201 K-202
Compressors Total Cost/Year Compressors Total Cost/Year K-300
1 $ 928,140.44 1 $ 4,124,658.09 Compressors Total Cost/Year
2 $ 960,210.75 2 $ 4,081,197.03 1 $ 1,749,431.52
3 $ 968,565.58 3 $ 4,144,069.67 2 $ 3,673,363.34
4 $ 4,328,521.09
5 $ 4,486,006.45
D.2: K-404 Optimization Analysis
$15,000,000.00
$14,500,000.00
$14,000,000.00
Cost Annually
$13,500,000.00
$13,000,000.00
$12,500,000.00
$12,000,000.00
$11,500,000.00
1 2 3 4 5 6 7
# Compressors
D.3: Compressor Hand Calculation Example
Assume polytropic behavior that approaches adiabatic (Perry's page 10-37)
( k 1) / k
p
T2 = T1 2 (10-67)
p1
3 mol
M := 13841 10
hr
T2 := ( 273.15 + 122.03)K T1 := ( 273.15 + 86.93)K
3 3
p 2 := 263.38 10 Pa p 1 := 135.78 10 Pa
5 kg G
G := 5.8282 10 M W :=
hr M
R c := 8.314
J 1
k := 1.1204
mol K M W
( k 1)
k
k R c T1 p 2
Had := 1 (10-64a)
k1
p 1
4
Had = 4.882 10 Sv
Pad := G Had (10-65a)
6
Pad = 7.904 10 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
hr := .00956 poise
Number of Tubes: w := .01241 poise

NP := 200
Temp. In and Out:
Cp at Bulk Temp.:
Tin := ( 28.2 + 273.15) K
J
C p := 1.542 1000
kg C Tout := ( 47.5 + 273.15) K
Totherin := ( 60 + 273.15) K
Length:
Length := 6 m Constants:
Density: n p := 2 Kc := 0.3 S := 0.5
kg
:= 2.224 kg m
3 kconstant := 0.000163
m 4
s A
Equations:
2 Mt
Ac := Di G :=
Ac NP
2 (
0.5 n p 1 ) Di G Cp
k := ( 1 S) + Kc + Re := Pr :=
np kconstant
Tin + Tout .2
Taverage := f := 0.046 Re
2

T1 := Totherin Taverage 0.28
0.51 k n p T1
w
0.14 B := 1 +

:= 1.02
2

w (Tout Tin) Pr
3
2 B f G2 Length n
P :=
p
Di
P = 80.234 Pa
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:
kg
M t := 1435000
hr := .41330 poise
kg
:= 1465 w := .4251 poise
3
m
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:
Ds Pd Lb Mt
Sm := Gs :=
Pt Sm
4 0.86 Pt 0.25 Do
2 2 Ls
De :=
Nb := 1
Lb + t b
Do
De Gs
Re :=

4 f G 2 D ( 1 + N )
P :=
s s b
0.14

2 De
w
P = 5.542 Pa
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 W W m
h air := 20 h s := 1000 ksteel := 45
2 2 2
m K m K m K
xsteel := 0.075m
Air and Styrene

1 kg
Utank := Utank = 18.987
1 xsteel 1 3
s K
+ +
h air ksteel hs
h := 36m D := 20m
2
A := D h +
D 3 2
A = 2.576 10 m
2
T := Tair Tsin T = 13.889 K

5
q := Utank A T q = 6.794 10 W
Water and Styrene
( Tsin Two ) ( Tso Twin)

Tlm := Tlm = 5.832 K
( Tsin Two )
ln
( Tso Twin)
W
Uhe := 425
2
m K
q 2
A := A = 274.11 m
Uhe Tlm
Appendix F: Reactor Sizing
F.1: Dehydrogenation Reactor Size
1 Time := 8000 hr
GHSV := 225 hr
mole
Molar_Flow := 19158000
hr
3
Molar_Flow m
Vol_Flow := Vol_Flow = 110.223
mole s
48.281
3
m
Vol_Flow
Vol :=
GHSV
3 3
Vol = 1.764 10 m
Numreactors := 4
Vol
Vol reactor :=
Numreactors
3
Vol reactor = 440.891 m
Appendix G: Economic Optimization
G.1: Investment Summary
Styrene Monomer Production Process
TOTAL
Direct Costs
Purchased Equipment Costs: $384.6
Delivery Costs: $38.5
Installation Costs: $198.8
Instrumentation & Controls: $152.3
Piping: $287.7
Electrical Systems: $46.5
Buildings: $76.2
Yard Improvements: $42.3
Service Facilities: $296.1
Total Direct Costs: $1,523.0
Total Direct Costs: $1,523.0

Indirect Costs
Engineering and Supervision: $139.6
Construction Expenses: $173.5
Legal Expenses: $16.9
Contractor's Fee: $93.1
Contingency: $186.1
Total Indirect Costs: $609.2
Total Indirect Costs: $609.2
FIXED CAPITAL INVESTMENT $2,132.2
Working Capital
Working Capital: $376.5

Total Working Capital: $376.5
TOTAL CAPITAL INVESTMENT $2,508.7
G.2: Economic Summary (1 of 5)
Raw Material, Product, & Utility Summary
Raw Material Price Annual Amount Annual Cost of Raw Material

($/kg) (million kg/yr) (million $)
Ethane 0.34 317.07 108.1
Benzene 0.83 704.93 581.8
Air 0.45 9.43 4.2
Dehydrogenation Catalyst 115.00 0.24 27.8
Alkylation Catalyst 105.00 0.02 1.7
Transalkylation Catalyst 40.00 0.01 0.3
TBC (Inhibitor) 63.80 0.02 1.4
DNP (Inhibitor) 260.00 0.02 6.2
Total 731.5
Product Price Annual Amount Annual Value of Product

($/kg) (million kg/yr) (million $)
Styrene 2.17 898.11 1950.3
Toluene 0.76 34.01 25.9
Total 1976.2
Utility Price Annual Amount Annual Cost of Utility

(million $)
Electricity 7.54 /kWh 1.16E+09 87.7
Refrigeration (to -50C) 14 $/GJ 5.68E+06 79.5
Steam, Saturated
3550 kPa (243.38C) 8 $/1000kg 1.51E+06 12.1
150 kPa (109.95C) 2 $/1000kg 3.88E+05 0.8
Water Treatment 36 $/1000kg 3.05E+05 11.0
Cooling Water (15C) 8 /m3 8.51E+07 6.8
Total 197.8
Purchased Equipment Cost Summary
Current Chemical Engineering Index (for 2006) = 493

Projected Chemical Engineering Index for 2007 = 519
Equipment Type Equipment Cost

(2007 MM$)
REACTOR VESSELS 6.447
DISTILLATION VESSELS 14.690
TRAY COSTS 2.411
HEAT EXCHANGERS 94.289
COMPRESSORS 189.822
PUMPS 0.115
TURBINES 69.590
STORAGE TANKS 9.644
TOTAL 387.008
Variable Cost Summary
Styrene Production Process
Per lb Styrene TOTAL

Raw Materials
Benzene $0.294 per lb of Styrene $581.8
Ethane $0.055 per lb of Styrene $108.1
Air $0.002 per lb of Styrene $4.2
Dehydogenation Catalyst $0.014 per lb of Styrene $27.8
Alkylation Catalyst $0.001 per lb of Styrene $1.7
Transalkyation Catalyst $0.000 per lb of Styrene $0.3
TBC (Inhibitor) $0.001 per lb of Styrene $1.4
DNP (Inhibitor) $0.003 per lb of Styrene $6.2
Total Raw Materials: $0.37 per lb of Styrene $731.5 $731.5
Utilties
High Pressure Steam $0.006 per lb of Styrene $12.1
Low Pressure Steam $0.000 per lb of Styrene $0.8
Cooling Water $0.003 per lb of Styrene $6.8
Refrigeration $0.040 per lb of Styrene $79.5
Electricity $0.044 per lb of Styrene $87.7
Waste Treatment $0.005 per lb of Styrene $11.0
Total Utilities: $0.0100 per lb of Styrene $197.8 $197.8
General Expenses
Operating Labor $0.001 per lb of Styrene $2.7
Operating Supervision $0.000 per lb of Styrene $0.4
Maintainance/Repairs $0.066 per lb of Styrene $131.4
Operating Supplies $0.010 per lb of Styrene $19.7
Laboratory Charges $0.000 per lb of Styrene $0.4
Total Byproducts: $0.078 per lb of Styrene $154.6 $154.6
TOTAL $0.547 per lb of Styrene $1,084.0 $1,084.0

Fixed Cost Summary
TOTAL
Fixed Charges
Property Taxes $43.8
Insurance $21.9
Total Fixed Charges: $65.7 $65.7
Plant Overhead
General Plant Overhead $80.7
Total Plant Overhead: $80.7 $80.7
General Expense
Administration $26.9
Distribution/Selling $69.1
Research & Development $55.3
Total General Expense: $151.3 $151.3
TOTAL $297.7
Cash Flow Summary
Percentage Depreciation Cumulative Net
Income Tax Annual Cash
Year of Design Sales Capital Costs Working Capital Variable Costs Fixed Costs Allowance Taxable Income Net Earnings Present Value at
Costs Flow
Capacity (MACRES) 15.0%
2007 0.0% Construction -$319.8 -$319.8 -$319.8
2008 0.0% Construction -$746.3 -$746.3 -$968.8
2009 0.0% Construction -$1,066.1 -$376.5 -$1,442.6 -$2,059.6
2010 45.0% $988.1 -$542.0 -$148.8 -426.4 $0.0 $0.0 $297.3 $297.3 -$1,864.1
2011 90.0% $1,976.2 -$1,084.0 -$297.7 -682.3 $0.0 $0.0 $594.6 $594.6 -$1,524.2
2012 90.0% $1,976.2 -$1,084.0 -$297.7 -409.4 $185.2 -$64.8 $529.7 $529.7 -$1,260.8
2013 90.0% $1,976.2 -$1,084.0 -$297.7 -245.2 $349.3 -$122.3 $472.3 $472.3 -$1,056.6
2014 90.0% $1,976.2 -$1,084.0 -$297.7 -245.2 $349.3 -$122.3 $472.3 $472.3 -$879.1
2015 90.0% $1,976.2 -$1,084.0 -$297.7 -123.7 $470.9 -$164.8 $429.7 $429.7 -$738.6
2016 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$628.7
2017 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$533.2
2018 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$450.2
2019 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$377.9
2020 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$315.1
2021 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$260.5
2022 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$213.0
2023 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$171.7
2024 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$135.8
2025 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$104.6
2026 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$77.4
2027 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$53.8
2028 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$33.3
2029 90.0% $1,976.2 $376.5 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $763.0 $2.0
**All numbers are in millions of dollars
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: $1,976.2

Annual Costs: -$1,381.7
Depreciation: $0.0
Income Tax: -$208.1
Net Earnings: $386.5
Total Capital Investment: $2,508.7
ROI: 15.40%
G.4: IRR Analysis - Product Price Fluctuation
Product Prices
Product Prices ($/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 $1.30 $1.40
Styrene Monomer Product Price ($/lb)

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Senior Design Final Report

Professor J.A. Sykes

ethylene to make ethylbenzene. 2.) A dehydrogenation reactor where ethylbenzene and

a purity of 99.93% styrene is achieved. Styrene can be produced at an estimated market

price of $0.99/lb with this process.

butadiene styrene (ABS), styrene-acrylonitrile, and various styrene-butadiene

meet future demand.2

of styrene remains largely dependant on the cost of its raw materials.3

Production of styrene requires two reactions, an alkylation and a dehydrogenation.

to form ethylbenzene by Reaction 1a:3

partially packed with catalyst. The benzene is in vapor-liquid equilibrium and it is

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

the bottoms of the distillation. They are sent to a transalkylation reactor to be

converted back to ethylbenzene by Reaction 1b:

Oligomerization products are caused by the partial polymerization of ethylene.

byproducts that include cumene, n-propylbenzene, butylbenzenes as well as other

toluene and C6 non-aromatics can be present in the benzene feedstock, up to

The dehydrogenation occurs in a fluidized catalyst cracking reactor, or FCC.6 An

continuous catalyst regeneration. The catalyst is comprised of gallium oxide

on alumina.7 It is unique in that is used to simultaneously dehydrogenate ethane and

ethylbenzene via reactions 2a and 2b:

form toluene, benzene and coke, as shown in Reactions 2c and 2d:

Coke (Rxn 2d)

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

For example, dehydrogenated cumene becomes -methylstyrene and n-

propylbenzene becomes allylbenzene. Other byproducts include vinlytoluenes,

xylenes, ethyltoluenes, phenylacetylene, unconverted alkylation byproducts and

greatly affect the cost of purification and quality of the product.3

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

styrene product. In the distillation columns 2,4-Dinitrophenol is fed continuously.10

monomer, this is equal to the industry standard.

2.) To analyze the design to determine whether it is economically competitive at the

average market price over the past three years

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.

be safe, even in the case of an accident. Customers need to be able to

the specification needed. Customers rely on knowing that the process

in designing a chemical processing plant. Making sure that the plant is

optimized to not have more adverse affects on the environment than is

waste, but are used to their fullest potential. Additionally, optimized

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

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

production of styrene from ethylene and benzene via an ethylbenzene intermediate.

benzene and propylene.

process to produce styrene. A basic Friedl-Crafts Alkylation occurs between

ethylene and benzene forming ethylbenzene. The ethylbenzene is then

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

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

hinder the polymerization of styrene, a major concern for the customer.3