PROPYLENE PRODUCTION PLANT 
 

 
 
 
 
 
 
 

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 TABLE OF CONTENTS

Page
TABLE OF CONTENTS 2

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CHAPTER 1 INTRODUCTION
1.1 Background of Propylene 5
1.2 Uses of Propylene 6
1.3 Propylene Manufacturing 8
1.4 Market Survey 9
1.5 1.4.1 Introduction 9
1.4.2 Production of Propylene 9
1.4.3 Propylene Consumption 11
1.4.4 Outlook for Production of Propylene in Malaysia 12
1.4.5 Market Prices of Polypropylene 12
1.5 Raw Materials 14
1.5.1 Source of Raw Materials 14
1.5.2 Raw Material Specifications 14

CHAPTER 2 PROCESS SYNTHESIS STEP

2.1 Step 1-Eliminate Differences in Molecular Type 15
2.2 Step 2- Distribute the Chemicals 24

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 2.2.1 Basic Material Balances 24
2.3 Step 3- Eliminate Differences in Compositions 26
2.4 Step 4 –Eliminate Differences in Temperature, Pressure and Phase 28
2.5 Step 5- Task Integration 30

CHAPTER 3 MATERIAL,ENERGY BALANCES AND PROCESS SIMULATION

3.1 Material Balance 33
3.1.1 Overall Mass Balances 33
3.1.2 Mass Balances for Separation Unit 1 35
3.1.3 Mass Balance for Mixer 36
3.1.4 Mass Balance for Reactor 37
3.1.5 Mass Balance for Separation Unit 2 38
3.1.6 Mass Balance For Separation Unit 3 39
3.1.7 Mass Balance For Separation Unit 4 40
3.2 Energy Balances 40
3.3 Simulation Result from ASPEN HYSYS 60
3.3.1 Material Balance 60
3.3.2 Energy Balances 60
3.4 Percentage Differences between Manual Calculation and HYSYS 61

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 3.4.1 Mass Balances 61
3.4.2 Energy Balances 61

CHAPTER 4: HEAT INTEGRATION

4.1 Process Energy Integration 62
4.2 ​Algorithm Table 63
4.3 Heat Exchanger Network 64
4.4 Process Flow Diagram Heat Exchanger Network 64

CHAPTER 5: PROCESS OPTIMIZATION 66

CHAPTER 6: EQUIPMENT SIZING AND COSTING

6.1 Introduction 69
6.2 Reactor 69
6.2.1 Sizing of reactor 69
6.2.2 Costing of reactor 70
6.3 Pump 70
6.3.1 Sizing of pump 70
6.3.2 Costing of pump 70

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6.4 Distillation columns (S1) 70
6.4.1 Sizing and costing of the main vessel 70
6.4.2 Sizing and costing of the reflux drum 71
6.4.3 Sizing and costing of the condenser 72
6.4.4 Sizing and costing of the re-boiler 73
6.5 Compressor 74
6.5.1 Sizing of compressor 74
6.5.2 Costing of compressor 74
6.6 Heat exchanger (HE2) 74
6.6.1 Sizing of Heat exchanger (HE 2) 74
​6.6.2 Costing of Heat Exchanger (HE2) 76

CHAPTER 7: TOTAL CAPITAL INVESTMENTS 77

CONCLUSIONS 79

APPENDICES A
APPENDICES B
APPENDICES C
APPENDICES D
APPENDICES E

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7
 CHAPTER 1

INTRODUCTION

1.1 Background of Propylene

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 Propylene, also called propene is generally described as a volatile and a colorless gas at room temperature. It has same empirical formula with cyclopropane
but different ways of atom connected. Propylene is categorized as a alkene hydrocarbon compound with a molecular formula of C​3​H​6​. The presences of the double
bond make it slightly lower boiling point than propane and thus more volatile. The existences of natural propylene are in the environment from sources such as
vegetation and combustion such as fires, motor vehicle exhaust, and tobacco smoke. Propylene is not expected to persist in the environment. Since propylene is a gas,
the exposure of propylene into the air is expected to be lower amount when released into the environment. Because of its relatively short half-life in the atmosphere
and typically low environmental concentrations, propylene’s contribution to potential global warming is considered minor and its ozone depletion potential is
negligible.

Figure 1: Structural formula of Propylene.

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 Propylene reacts violently with oxide of nitrogen and also a number of other substances and condition. Essentially all of the propylene produced for chemical
purposes is consumed as a chemical intermediate in other chemical manufacturing processes. This hydrocarbon is widely used in the manufacture of cumene, resins,
fibres, elastomers and other chemicals which enable the manufacture of many chemicals and plastics. In addition to its use as a chemical intermediate, propylene is
produced and consumed in refinery operations for the production of gasoline components.

1.2 Uses of Propylene

Propylene is a major product of the petrochemical industry. It is one of the highest volume chemicals produced globally. Propylene is primarily used as an
intermediate for the production of other chemical raw materials that are subsequently used to manufacture a large variety of substances and products. Manufacture of
polypropylene, a widely used plastic, consumes more than half of the world’s production of propylene. Propylene is also used in the manufacture of acrylonitrile, oxo
process chemicals, cumene, isopropanol, polygas chemicals, and propylene oxide. Table 1.1 below highlights several of the main applications of propylene and its
derivatives.

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 Table 1.1: Selected Propylene Application

Product Application Application Description

● Polypropylene is used to make many well-known plastic

Polypropylene
products.
● Polypropylene resins can be injection molded and extruded
(into fibers, film, and sheets) to make a variety of products.
● Polypropylene may also be blow-molded or thermoformed,
but these processes are less often used.
● Polypropylene is extremely corrosion resistant, lightweight,
flexible, and formed or welded.

● Used mainly as a chemical intermediate in the production of

Propylene Oxide
polyurethane polyols and propylene glycols.
● Used in the manufacture of propylene glycol, which helps to
make antifreeze, resins for reinforced plastics,
pharmaceuticals, packaging materials, dyes, and hydraulic
fluids, and humectants for foods, drugs, cosmetics, and pet
foods.
● Derivatives of propylene oxide include polyether polyols;
propylene glycol; di- and tripropylene glycol; poly
(propylene glycol)s; surfactants; glycol ethers; and
isopropanolamines.

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 ● A variety of solvent applications, such as in printing inks,
Isopropanol
surface coatings, and as a solvent for resins, shellacs, and
gums.
● As a component of personal care products, such as
after-shaves; and as an antiseptic and disinfectant, such as
rubbing alcohol.
● Used in the production of acetone, methyl isobutyl ketone
(MIBK), iso-propylamines and isopropyl acetate.

● Alkylation of benzene with propylene yields cumene.

Cumene
● Consuming in phenol production for the manufacture
phenolic resins, caprolactam and bisphenol A.

● About half of the worldwide production of EP elastomer

Ethylene-Propylene
goes into the manufacture of automobile body and chassis
Elastomers
parts, hoses, weatherstripping, and tires.
● Also used to make thermoplastic polyolefin elastomers,
polymer modifiers, and other products used in automobile
components beside used in single-ply roofing.

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 ● Propylene is used to manufacture Isobutyraldehyde, which is
Oxo Process Chemicals
converted to isobutanol solvent for surface coatings.
● Propylene is also used to make n-Butyraldehyde, which is
converted to n-butanol or 2-EH. n-Butanol is a solvent for
lacquers and coatings, and is an intermediate for several
chemicals.

● Refinery production of polymer gasoline also yields nonene,

Polygas Chemicals
dodecene and heptene and propylene is consumed to yield
(nonene, dodecene,
these polygas chemicals.
heptenes)
● Nonene is used in nonylphenol and isodecyl alcohol that act
as an intermediate for surfactants, lubricating oil additives,
and phosphite antioxidants.
● Heptenes are consumed to make isooctyl alcohol, which is
used in the manufacture of another phthalate ester.

1.3 Propylene Manufacturing

Lotte Chemical Titan Holding Sdn. Bhd. is one of the manufacturer and supplier of propylene, located at Pasir Gudang, Johor Bahru. This company will be the
benchmark of Equinox Team to design a plant that can produce 100,000 lb/hr of propylene. The team will propose a variety of production reactions of propylene and
there are several production processes such as catalytic dehydrogenation of propane, reformation of olefins reaction (metathesis reaction), and the conversion of

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methanol to propylene. The most sustainable and economically reaction processes will be chosen for the plant design. This includes the comparison between the cost
of raw materials, safety, environmental impacts, percentage yield of conversion, energy consumption, and other factors that might affect the reaction process.

1.4 Market Survey

1.4.1 Introduction

Market survey or market outlook will cover a review on the production and consumption of propylene in addition to that there will be another section to
discuss the prices of propylene and its raw materials.

1.4.2 Production of Propylene

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 Propene production increased in (Europe and North America only) from 2000 to 2008, it has been increasing also in East Asia, most notably Singapore and
China. Total world production of propene is currently about half that of ethylene. About 56% of the worldwide production of propylene is obtained as a co-product of
ethylene manufacture, and about 33% is produced as a by-product of petroleum refining. About 7% of propylene produced worldwide is on-purpose product from the
dehydrogenation of propane and metathesis of ethylene and butylenes; the remainder is from selected gas streams from coal-to-oil processes and from deep catalytic
cracking of vacuum gas oil (VGO). The supply of propylene remains highly dependent on the health of the ethylene industry as well as on refinery plant economics.

In 2010, production of polypropylene represented 65% of total world propylene consumption, ranging from 53% in North America to more than 90% in Africa
and the Middle East.

Table 1.2: Annual Production of Propene (Propylene)

World 80.0 million tones

Europe 14.3 million tons

US 14.3 million tones

Figure 1.1 below shows how the production of propylene increased from 11 million tons in 1994 to 16 million tons in 2007 but it had dropped since that time
to 14.3 million tons in 2013.

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 Figure 1.1:​ Wastern European Propylene Capacity, Production and Consumption 1994-2013

Top world companies are leading the production of propylene with LyondellBasell, Netherlands on top of propylene producing companies by 2009. The top
propylene-producing companies are listed as bellow:

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 Figure 1.2:​ Propylene top producers

1.4.3 Propylene Consumption

After experiencing zero growth or declines in 2008 and 2009, global propylene consumption grew at a rate of almost 7.5% in 2010, led by Asia at 11%
year-on-year. The economic recession of 2008/2009 reflected both a reduction in pull-through demand for polypropylene, as well as a supply-chain inventory

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rundown, reminiscent of the early 1980s downturn. World petrochemical industries have historically witnessed very few upheavals that combined the effects of both
energy volatility and depressed downstream demand.

The fifteen largest worldwide producers of propylene accounted for almost 51% of world capacity as of 2010, representing about the same level of
concentration as five years ago. The most significant changes in the last two years have been Sinopec taking over the top spot, a position long occupied by
ExxonMobil, and PetroChina jumping from the seventh spot to number four.

World consumption of propylene is forecast to grow slightly better than global gross domestic product (GDP) rates over the next five years. Average growth
will be 5% per year, higher than GDP in general and higher than ethylene specifically, with growth for polypropylene being much better than that for polyethylene.
Growth will be led by the Middle East, Asia, Central and Eastern Europe, and South America at 12.5%, 6.5%, 5%, and 4.5% per year, respectively. Asia is a mixed
bag of growth rates with China and India at 8–10% annually and the mature economies of Japan, the Republic of Korea, and Taiwan at 1–2% per year. Near-term
growth will be relatively slow in the mature economies of North America and Western Europe.

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 Figure 1.3: ​World Consumption of Propylene in 2010

1.4.4 Outlook for Production of Propylene in Malaysia

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 Malaysia’s petrochemical sector has contributed significantly to the development of local downstream plastic processing activities. Malaysia is one of the
largest plastics producers in Asia, providing a steady supply of feedstock materials for the plastic processing industry such as propylene.

Table 1.3: ​Production, Import, Export and Consumption of PP in Malaysia

Product Unit: KTPA 2007 2008 2009 2010 change

Propylene Production 839 870 867 808 0.3%

Import 33 40 25 8 0%

Export 78 97 95 50 -2%

Consumptio 765 811 797 744 -5%

n

1.4.5 Market Prices of Polypropylene

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 Polypropylene prices are on the rise since the last decade and it is expected to continue rising as the demand increases for the chemical material, Capacity
and Prices for Polypropylene - End-Use Sectors in Asia-Pacific to Drive Growth" 2014 market research report says worldwide polypropylene capacity increased at a
Compound Annual Growth Rate (CAGR) of 5.2% from 2003, reaching 65 million tons per year (MMTY) in 2013, and is expected to continue rising to 86 MMTY by
2018, at a slightly higher CAGR of 5.8%. It forecasts China and Russia to be the leading contributors to future polypropylene capacity increases, and will account for
a combined 45% of global additions over the next five years. As Malaysia is part of the global market it is normal for prices in Malaysia to be affected by the global
prices, following are prices of PP and its raw material (propane, ethylene, butene and methanol) as achieved from ICIS.com.

Table 1.4: ​Propylene and raw products prices

Price
Product
RM/Ib RM/Kg

Propylene 1.962 4.326

Propane 0.79 1.742

Ethylene 2.158 4.758

Butene 1.118 2.465

Methanol 1.635 3.609

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1.5 Raw Materials

1.5.1 Source of Raw Materials

The raw material that is utilized in this process is liquefied petroleum gas (LPG) propane. The term LPG actually encompasses more than one variety of
gaseous fuel. There are a number of hydrocarbon gases that fall into the classification of “LPG”. Their common distinguishing characteristic is that they can be
compressed into liquid at relatively low pressures. LPG is stored under pressure, as a liquid, in a gas bottle. It turns back into gas vapor when you release some of
the pressure in the gas bottle by turning on your appliance. Almost all of the uses for LPG involve the use of the gas vapor, not the liquefied gas.

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 The gases that fall under the “LPG” label, including Propane, Butane, Propylene, Butadiene, Butylene and Isobutylene, as well as mixtures of these gases.
The two most common are Propane and Butane.

The main supplier of LPG used in this process is Kleenheat Gas which is part of Wesfarmers Chemicals, Energy and Fertilizers, one of eight divisions of
Wesfarmers Limited, with origins dating back to 1914.

They have a long history in the Australian gas industry with over 55 years of experience retailing and distributing Liquefied Petroleum Gas (LPG), over a
decade of experience distributing Liquefied Natural Gas (LNG) and advancing technology through their brand EVOL LNG, and most recently retailing natural gas in
Western Australia.

1.5.2 Raw Material Specifications

Table 1.5:​ LPG propane supplied by Kleenheat Gas Australia

LPG specification

CAS Number 74-98-6

Component Mole percentage (%)

Propane 80

Butane 18

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 Butanes ,pentanes ,butadiene and heavier 2

CHAPTER 2

PROCESS SYNTHESIS STEP

2.0 SYNTHESIS STEPS

Process synthesis involves the selection of processing operations to convert raw materials to products, given that the states of the raw material and product
streams are specified. The most widely accepted approach for process synthesis is introduced by Rudd, Powers, and Siirola (1973) in a book entitled ​Process
Synthesis.​ There are 5 key synthesis steps which are:

1. Eliminate differences in molecular types

2. Distribute the chemicals by matching sources and sinks

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 3. Eliminate differences in composition
4. Eliminate differences in temperature, pressure, and phase
5. Task integration; combination of operations into unit processes and decide between continuous and batch processing

2.1 Step 1 – Eliminate Differences in Molecular Type

A. Propylene from Propane via Dehydrogenation

Dehydrogenation is an endothermic equilibrium reaction; it is carried out in the presence of heavy-metal catalyst (chromium). The following equation
shows the propane dehydrogenation reaction:

Propane Dehydrogenation Reaction

About 86 wt% of propane is converted to propylene. To mitigate cracking reactions, dehydrogenation reaction in this technology occurs in conditions such as
temperature ranges between 580 and 650 °C, and pressures slightly below atmospheric. For further information, Table 2.1 shows the thermophysical property
data for this process.

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Figure 2.1:​ Commercial process flow diagram (Dehydrogenation)

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 Figure 2.2:​ Detailed process flow diagram (Dehydrogenation)

Process Description of Propylene Dehydrogenation

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 The propane dehydrogenation process is used to supply polymer-grade propylene from propane to meet the growing propylene market, independent of
a steam cracker or Fluid Catalytic Cracking (FCC) unit. It provides a dedicated, reliable source of propylene to give more control over propylene feedstock
costs.

From Figure 2.2, the process flow diagram consists of a reactor section, product recovery section and catalyst regeneration section. Hydrocarbon feed
is mixed with hydrogen-rich recycle gas and is introduced into the heater to be heated into the desired temperature (over 540 °C) and then enter the reactors to
be converted at high mono-olefin selectivity. Several interstage heaters are used to maintain the conversion through supplying heat continuously since the
reaction is endothermic. Catalyst activity is maintained by continuous catalyst regenerator (CCR) or shutting down reactors one by one and regenerating the
reactor by the regeneration air, the continuous catalyst regenerator is where the catalyst is continuously withdrawn from the reactor, then regenerated, and fed
back to the reactor bed.

Reactor effluent is compressed, dried and sent to a cryogenic separator where net hydrogen is recovered. The olefin product is sent to a selective
hydrogenation process where dienes and acetylenes are removed. The propylene stream goes to a de-ethanizer where light-ends are removed prior to the
propane-propylene splitter. Unconverted feedstock is recycled back to the depropanizer where it combines with fresh feed before being sent back to the reactor
section.

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 Table 2.1: Physical And Chemical Properties Of Reactant And Product For Dehydrogenation Reaction

REACTION PROPANE ​→ PROPYLENE HYDROGEN

Properties
Molecular formula C​3​H​8 C​3​H​6 H​2
Molar mass 44.10 g mol​−1 42.08 g mol​−1 2.016 g mol​-1
Appearance Colourless gas Colourless gas Colourless gas
Odor Odourless Gassy/ aromatic
Density 2.0098 mg mL​−1​ (at 0 1.81 kg/m​3​, gas (1.013 0.08988 g/L (at 0 °C,
°C, 101.3 kPa) bar, 15 °C) 101.325 kPa)
613.9 kg/m​3​, liquid
Melting point −187.7 °C; −305.8 °F; − ,185.2 °C (−301.4 °F; 13.99 ​K​ ​(−259.16 °C,
85.5 K 88.0 K) ​−434.49 °F)
Boiling point −42.25 to −42.04 °C; − 47.6 °C (−54 °F; 20.271 K ​(−252.879 °C,
−44.05 to −43.67 °F; 226 K) ​−423.182 °F)
230.90 to 231.11 K
Solubility​ in ​water 40 mg L​−1​ (at 0 °C) 0.61 g/m​3
Vapor pressure 853.16 kPa (at 21.1 °C) 144.06 psia 100kPa (at 20 ºC)
Thermochemistry
Std enthalpy of −105.2–−104.2 kJ mol​−1 +20.41 kJ/mol 0
formation​ Δ​f​Ho​​ 298

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Std enthalpy of −2.2197–−2.2187 MJ -2058.4 kJ/mol -285.84 kJ/mol
combustion​ Δ​c​Ho​​ 298 mol​−1

To screen out whether this reaction will bring profit or not, the gross profit is calculated as shown below:

C​3​H​8​ ​→​ C​3​H​6 +​ H​2

C​3​H​8 C​3​H​6 H​2

lbmol 1 1 1

Molecular weight 44.09 42.08 2.016

lb 44.09 42.08 2.016

lb/lb of propylene 1.0478 1 0.048

RM/lb 0.79 1.96 11.30

Gross profit for reaction path 1 = 1.96(1) + 11.30(0.048) – 1.0478(0.79) = ​RM 1.67 /lb propylene

B. Propylene from Ethylene and Butenes via Metathesis

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 Metathesis is a general term for a reversible reaction between two olefins, in which the double bonds are broken and then reformed to form new olefin
products. In order to produce propylene by metathesis, a molecule of 2-butene and a molecule of ethylene are combined to form two molecules of propylene.
Some of the thermophysical property data is shown on table 2.

Metathesis Reaction

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 Figure 2.3:​ Commercial process flow diagram (Metathesis)

Figure 2.4:​ Detailed process flow diagram (Metathesis)

Process Description of Metathesis of Ethylene and Butene

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 Propylene is formed by the metathesis of ethylene and butene-2, and butene-1 is isomerised to butene-2 as butene-2 is consumed in the metathesis
reaction. In addition to the main reactions, numerous side reactions between olefins also occur. Ethylene feed can be polymer grade ethylene or a dilute
ethylene stream. Any saturated hydrocarbons, such as ethane and methane, do not react.

From Figure 2.4, fresh C​4​s (plus C​4 recycle) are mixed with ethylene feed (plus recycle ethylene) and sent through a guard bed to remove trace
impurities from the mixed feed. The feed is heated prior to entering the vapour phase fixed-bed metathesis reactor where the equilibrium reaction takes place.
The reactor is regenerated in-situ on a regular basis. The catalyst promotes the reaction of ethylene and butene-2 to form propylene and simultaneously
isomerises butene- 1 to butene-2. The per-pass conversion of butylene is greater than 60 per cent, with overall selectivity to propylene exceeding 90 per cent.

The product from the metathesis reactor is primarily propylene and unreacted feed. Reactor effluent is sent to the ethylene recovery tower where the
unreacted ethylene is recovered and recycled to the reactor. The C​2 tower bottom is processed in the C​3 tower to produce propylene product and a C​4 recycle
stream. Purge streams containing non-reactive light material, C​4​s and heavier are also produced. Ultra-high purity propylene exceeding polymer grade
specification is produced without a propylene fractionation system, since the only source of propane is that contained in the C​4​ and ethylene feeds.

Table 2.2: Physical And Chemical Properties Of Reactant And Product For Metathesis Reaction

REACTION ETHYLENE BUTENE ​→ PROPYLENE

Properties
Molecular formula C​2​H​4 C​4​H​8 C​3​H​6
Molar mass 28.05 g/mol 56.10 g/mol 42.08 g mol​−1
Appearance Colorless gas colorless Colorless gas
Odor Odorless odorless Gassy/ aromatic

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Density 1.178 kg/m​3​ at 15 °C, gas 0.62 g/cm​3 1.81 kg/m​3​, gas (1.013 bar,
15 °C)
613.9 kg/m​3​, liquid
Melting point −169.2 °C (104.0 K, −185.3 °C (−301.5 °F; − ,185.2 °C (−301.4 °F;
-272.6 °F) 87.8 K) 88.0 K)
Boiling point −103.7 °C (169.5 K, −6.47 °C (20.35 °F; − 47.6 °C (−54 °F; 226 K)
-154.7 °F) 266.68
Solubility​ in ​water 3.5 mg/100 mL (17 °C)​[ 0.61 g/m​3
Thermochemistry
Std enthalpy of 52.28 kJ mol​−1 1.17 kJ/mol +20.41 kJ/mol
formation​ Δ​f​H​o​298
Std enthalpy of -1410.99 kJ mol​−1 -2718.6 kJ/mol -2058.4 kJ/mol
combustion​ Δ​c​Ho​​ 298

To screen out whether this reaction will bring profit or not and whether it is better from reaction A, the gross profit is calculated as shown below:

C​2​H​4​ + C​4​H​8​ ​→​ 2C​3​H​6

C​2​H​4 C​4​H​8 C​3​H​6

lbmol 1 1 2

Molecular weight 28.05 56.10 42.08

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lb 28.05 56.10 84.16

lb/lb of propylene 0.33 0.667 1

RM/lb 2.16 1.18 1.96

Gross profit for reaction path 2 = 1.96(1) – 2.16(0.33) – 1.18(0.667) = ​RM 0.46 /lb propylene

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 Table 2.3: Summary of Review and Screening of Alternative Processes
Metathesis of from
Dehydrogenation of propane
Ethylene & Butenes
C​3​H​8​ ​→​ C​3​H​6​ + H​2
C​2​H​4​ + C​4​H​8​ ​→​ 2C​3​H​6

Gross Profit
RM 1.67 / lb propylene RM 0.46/lb propylene
(Appendix 1)

Type of process Continuous process Continuous process

Butane and ethylene is

Safety Propane is flammable​. flammable, and ethylene also
may cause dizziness

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 By-product Hydrogen No by-product

Temperature: 560 – 650 ºC

Operating Temperature: 90-100ºC
Pressure : slightly below atmospheric
condition Pressure: 100 – 110 bar
pressure

Conversion 86% percent of conversion 90% percent of conversion

Flammability Flammable Flammable

From the table above, it shows that the dehydrogenation of propane reaction is a better process compared to the metathesis reaction.

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2.2 Step 2 – Distribute the Chemicals

2.2.1 Basic Material Balance

Overall Reaction Equation :

C​3​H​8 C​
​ 3​H​6 +
​ H​2

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Basis : 100000 lb/hr of propylene (C​3​H​3​)
86% of conversion

C​3​H​8 C​3​H​6 H​2

stoichiometry 1 1 1

Mass flowrate (lb/hr) m​1 m​2​=100,000.00 m​3

MW (lb/lbmol) 44.10 42.08 2.01

n, (lbmole/hr) 2376.43 2376.43 2376.43

Number of moles of propylene formed

= (100,000 lb/hr)/42.08
= 2376.43 lbmole/hr C​3​H​6

Assume 100% conversion, the mass flow rate of feed, m​1​ = 2376.43 x 44.1
= 104800.56 lb/hr

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for 86% conversion, the mass flow rate of recycle, R = (1-0.86)/0.86 x 104800.56
R = 17060.53 lb/hr
Mass flowrate of H​2 ,​ m​3
= (no. of mole) X (molecular weight)
= (2376.43) x (2.01)
=​ 4776.62
​ lb/hr

Mass flowrate feed to the reactor, F = m​1​ + R

= 104800.56 + 17060.53 = 121861.09lb/h
2.3 Step 3 – Eliminate Differences in Composition

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 Figure 2.5:​ Flowsheet with separation units of propylene production process

In order to enable all chemicals involved to be supplied to their sinks, separation operations are needed. Figure 2.5 shows the separation units that are needed
in a propylene production process. Since the raw material using in this process is from LPG that consists 80% propane, 18% butane and 2% pentane, so S1 as a
separating unit is needed to separate propane from butane and pentane. However, the separation is not perfect. There will still have some butane and pentane that will
be distillate but in a small proportion. As referred to table 2.4, S1 will be operated at 15bar. The bubble point at distillate product is 47˚C and the dew point of
mixtures at the bottom product is 110.7˚C.

When the separation between propane, butane and pentane is done, propane as a reactant will enter the reactor which will be operate at 600˚C and 1 bar. These
pressure and temperature is selected because the dehydrogenation process of propylene only will occur at these conditions.

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 After the reaction occurs, there have a lot of products produced. In order to separate the products, 3 separation units will be used. The first product that will be
separated is hydrogen gas. The reason is, hydrogen gas has a low value of critical pressure and it will be difficult to separate the other products if the hydrogen
maintain in the product mixtures. S2 will be used as separation unit that will be operated at pressure 10 bar and temperature -137.1 at dew point of vapor of the
product mixture.

Next, after separate hydrogen gas, we will separate propane and propene from the side product. From Table 2.4 at 1 atm, the boiling point of C​3 is very low, -
48˚C, and hence if C​3 were
​ recovered at 1 atm as the distillate of the S3, very costly refrigeration would be necessary to condense the reflux stream. At 18 bar , the
bubble point of propane and propylene mixture is at 40˚C and much less cost refrigeration could be used. The bottom products which are consists butane, butene and
pentane has a dew point 108.4˚C at 17.5 bar.

After separation unit S3 is inserted into the process design, S4 follows naturally. The distillate from S3 is separated into nearly pure species in the S4, which is
specified at 15 bar. Under these conditions, the distillate (nearly pure propylene) boils at 33˚C and can be condensed with inexpensive cooling water, which is
available at 25˚C. However, S4 need special separation unit due to small difference of boiling point between propane and propylene.

Table 2.4​: Boiling points and critical constant

Normal Critical constant

Boiling point (˚C)
Chemical boiling point

(1atm, ˚C)
15 bar 17.5 bar 20 bar T​c​ (˚C) P​C​ (bar)

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 H​2 -252.78 - - - -240.01 12.96

C​3​H​8 -42.11 41.00 45.00 53.55 96.74 42.51

C​3​H​6 -47.62 33.00 35.85 42.65 91.06 45.55

2.4 Step 4 – Eliminate Differences in Temperature, Pressure, and Phase

43
44
 Figure 2.6​: Flowsheet with temperature-, pressure-, and phase-change operations in the propylene production process.

Figure 2.6 shows the changes of the state of chemicals. Since the original state of the raw material (LPG) is at 20°C and 18 bar, its temperature is raised to
52°C at 15 bar. The LPG is then introduced into a separation column (S1) at 15 bar with 99% conversion that separates the propane gas from other LPG products.
Here, only 99% of LPG is converted to propane gas where another 1% is butane gas and pentane gas.

The process begins by mixing the upper products from S1 (propane gas, butane gas and pentane gas) with a stream of recycle propane gas at 47°C and 15 bar.
The mixing of upper products from S1 and recycle propane undergoes the following operations:

1. The product mixture is preheated before it is introduced to the reactor. The reaction occurs at around 600​o​C and 1 bar.
2. The products mixture is then cooled to its dew point -137.1​o​C at 10 bar.
3. Then, the product mixture is introduced into a condenser (S2) that separates the hydrogen gas from other liquid products.

In addition, the liquid mixture that condensed at -137.1​o​C at 10 bar from the condenser is operated upon as follows:

1. Its pressure is increased to 17.5 bar.

2. The temperature is then raised to a liquid at its bubble point, 42​o​C at 17.5 bar.
3. Then, the liquid mixture is introduced into a separation column (S3) that separates the propane gas and propylene gas from other liquid products.

Next, the upper products (propane gas and propylene gas) from separation column (S3) are then entered into separation column (S4) at 40​o​C. The propylene gas
with a boiling point of 33​o​C at 15 bar is come out as an upper product from separation column (S4).

45
 Finally, the propane liquid from the recycle stream (at 42​o​C and 15 bar) undergoes the operation where ​its temperature is raised to the mixing temperature at 47 o​C
at 15 bar.

46
2.5 Step 5 – Task Integration

Figure 2.7 shows task integration for the propylene production process. At this stage in process synthesis, it is common to make the most obvious combinations of
operations, leaving many possibilities to be considered when the flowsheet is sufficiently promising to undertake the preparation of a base case design. Below are the
descriptions of unit process shown in Figure 2.7:

1. Heat exchanger

Heat exchanger is needed to increase or decrease the temperature of the stream. A heat exchanger is a piece of equipment built for efficient heat transfer from
one medium to another. The media may be separated by a solid wall to prevent mixing or they may be in direct contact.

2. Depropanizer

A propane rich liquefied petroleum gas (LPG) feedstock is sent to a depropanizer to reject butanes and heavier hydrocarbons.

3. Furnace

Since the outlet temperature from the mixer is 47˚C and we need to increase the temperature to 600˚C, the furnace is used to heat up the stream. This follows
heuristics 26 which explained near-optimal minimum temperature approaches in heat exchangers depend on the temperature level. For 250 to 350˚F, the

47
 stream must be heat up in a furnace for flue gas temperature above inlet process fluid temperature. An industrial furnace or direct fired heater is equipment
used to provide heat for a process or can serve as reactor which provides heats of reaction. Furnace designs vary as to its function, heating duty, type of fuel
and method of introducing combustion air.

4. Oleflex Reactor

The UOP Oleflex process is a catalytic dehydrogenation technology for the production of light olefins from their corresponding paraffins. One specific
application of this technology produces propylene from propane. The Olexflex process uses a platinum catalyst to promote the dehydrogenation reaction

5. Pump

Since the pressure change operation involves a liquid, it is accomplished by a pump, which requires only 66 Bhp, assuming an 80% efficiency. The enthalpy
change in the pump is very small and the temperature does not change by more than 1˚C

6. Distillation Column

48
 To separate the mixture of C​3 and butane, butane and pentane, distillation column is selected as the best separation unit. Distillation is based on the fact that
the vapour of a boiling mixture will be richer in the components that have lower boiling points. Therefore, when this vapour is cooled and condensed, the
condensate will contain more volatile components. At the same time, the original mixture will contain more of the less volatile material.

7. Propane-Propylene Splitter

C​3 splitters are frequently designed with vapor-recompression heat pumps when sufficient low-energy heat sources are not available. The heat of vaporization
of propylene and propane at 100psia are nearly identical. The only energy needed for a C​3 splitter heat pump is the compressor duty, which is typically only
11-12% of the total reboiler duty. Therefore, the energy savings are significant. In addition, C​3 splitter heat pump system operates at much lower pressure than
conventional columns without heat pumping. The high-pressure compressor discharge stream is the same as the conventional tower’s top pressure.

49
50
 process

CHAPTER 3

MATERIAL AND ENERGY BALANCES AND PROCESS SIMULATION

3.1 MATERIAL BALANCES

3.1.1 Overall Mass Balance

51
Overall Reaction Equation :
C​3​H​8 C​
​ 3​H​6 +
​ H​2

Basis : 100000 lb/hr of propylene (C​3​H​3​)

86% of conversion

C​3​H​8 C​3​H​6 H​2

stoichiometry 1 1 1

Mass flowrate (lb/hr) m​1 m​2​=100,000.00 m​3

MW (lb/lbmol) 44.10 42.08 2.01

52
n, (lbmole/hr) 2376.43 2376.43 2376.43

53
3.1.2 Mass Balance for Separation Unit 1

Stream 1 Stream 2 Stream 3

No Mass Mass Mass
Component Mole Mole Mole
. Flowrate, Flowrate, Flowrate,
Fraction Fraction Fraction
(lb/hr) (lb/hr) (lb/hr)

1 Propane 0.80 104800.56 0.990 104800.56 0 0

54
2 Butane 0.18 31076.58 0.009 1116.11 0.9 29960.47
3 Pentane 0.02 4286.49 0.001 346.38 0.1 3940.11

55
3.1.3 Mass Balance for Mixer

Stream 3 Stream 4 Stream 10

No Mass Mass Mass
Component Mole Mole Mole
. Flowrate, Flowrate, Flowrate,
Fraction Fraction Fraction
(lb/hr) (lb/hr) (lb/hr)

1 Propane 0.990 104800.56 0.991 121861.09 1.0 17060.53

2 Butane 0.009 1116.11 0.007 1116.11 0 0
3 Pentane 0.001 346.38 0.002 346.38 0 0

56
3.1.4 Mass Balance for Reactor

The percentage of conversion for propane and butane are 86% and 90% respectively and since the weight percent of pentane is too small, we assume that pentane is
remain unreacted.

Stream 4 Stream 5

No. Component Mass

Mole Mole Mass Flowrate,
Flowrate,
Fraction Fraction (lb/hr)
(lb/hr)

57
1 Propane 0.991 121861.09 0.0747 17060.53
2 Butane 0.007 1116.11 0.0004 111.61

3 Pentane 0.002 346.38 0.0009 346.38

4 Propene 0 0 0.4587 100000
5 Butene 0 0 0.0033 969.58
6 Hydrogen 0 0 0.4620 4811.36

3.1.5 Mass Balance for Separation Unit 2

58
 Stream 5 Stream 6 Stream 7

No. Component Mass Mass Mass

Mole Mole Mole
Flowrate, Flowrate, Flowrate,
Fraction Fraction Fraction
(lb/hr) (lb/hr) (lb/hr)

1 Propane 0.0747 17060.53 0 0 0.1388 17060.53

2 Butane 0.0004 111.61 0 0 0.0007 111.61
3 Pentane 0.0009 346.38 0 0 0.0017 346.38
4 Propene 0.4587 100000 0 0 0.8526 100000
5 Butene 0.0033 969.58 0 0 0.0062 969.58
6 Hydrogen 0.4620 4811.36 1 4811.36 - -

59
3.1.6 Mass Balance for Separation Unit 3

Stream 7 Stream 8 Stream 9

No. Component Mass Mass Mass

Mole Mole Mole
Flowrate, Flowrate, Flowrate,
Fraction Fraction Fraction
(lb/hr) (lb/hr) (lb/hr)

60
1 Propane 0.1388 17060.53 0.1400 17060.53 0 0
2 Butane 0.0007 111.61 0 0 0.08 111.61

3 Pentane 0.0017 346.38 0 0 0.20 346.38

4 Propene 0.8526 100000 0.8600 100000 0 0
5 Butene 0.0062 969.58 0 0 0.720 969.58

61
3.1.7 Mass Balance for Separation Unit 4

Stream 8 Stream 1 Stream 11

No. Component Mass Mass Mass

Mole Mole Mole
Flowrate, Flowrate, Flowrate,
Fraction Fraction Fraction
(lb/hr) (lb/hr) (lb/hr)

1 Propane 0.140 17060.53 1 17060.56 0 0

62
2 Propene 0.860 100000 0 0 1 100000

63
 3.2 ENERGY BALANCES

Table 3.1​: Table of Data for Heat of Capacities

C​p​=A+B*T+C*T​^-2​+D*T​^-3
C​p​=A+B*T+C*T​^-2​+D*T​^-3
Average Cp
Molecular ∆H​v
Compound ∆H​f for liquid
Weight
Kj/mol
A*10^3 B*10^5 C*10^8 D*10^12 KJ/(mol.K)

-103.
Propane 44.09 18.77 68.023 22.59 -13.11 31.71 0.10584
8

Propene 42.08 20.41 18.42 59.58 17.71 -10.17 24.6 0.1199

-124. 22.30
Butane 58.12 92.3 27.88 -15.47 34.98 0.13367
7 6

21.91
Butene 56.1 1.17 82.88 25.64 -17.27 50.50 0.09396
6

64
 -146.
Pentane 72.15 25.77 114.8 34.09 -18.99 42.26 0.167
4

Hydrogen 2.016 0 0.904 28.84 0.00765 0.3288 -0.8698 -

Energy Balance

We use heat of vaporization instead of liquid heat capacities to calculate the stream enthalpy and the value stated in Table 3.1. For a mixed stream, both
equations are applied based on the vapor/liquid fraction involved. If there is no reaction occur in a unit (i.e. initial component = final component), enthalpy change
for the unit is express as below:

65
Where, n is the total molar flow rate of that specific stream
For streams with composition or component change (i.e. reactor), heat of formation must be included.

3.2.1 Separation Unit 1

66
For Stream 1
Liquid phase
Stream temperature, T = 325.13 K and consider datum at 298.13 K

Flow rate Flow rate ∆H

Component C​p
Ibmole/hr mole/hr KJ/hr

Propane 2376.43 1077948.64 0.10584 3080432.27

Butane 534.69 242535.38 0.13367 875332.014

Pentane 59.41 26948.37 0.167 121510.2

∑ 4077274.484 KJ/hr

For Stream 2
Liquid phase
Stream temperature, T = 320.13 K and consider datum at 298.13 K

67
 Flow rate Flow rate C​p
Component ∆H
Ibmole/hr mole/hr liquid

1077924.88
Propane 2376.43 0.10584 2509926.534
4

Butane 19.203 8710.288 0.13367 25614.69

Pentane 4.8 2177.23 0.167 7999.14

∑ 2543540.36 KJ/hr

68
For Stream 3
/Stream temperature, T = 377.13 K and consider datum at 298.13 K

Flow rate Flow rate C​p

Component ∆H
Ibmole/hr mole/hr liquid

Butane 8.86 4018.8 0.13367 42438.24

Pentane 0.756 342.91 0.167 4524.011

∑ 46962.25 KJ/hr

∑H=46962.25 +2543540.36 -4077274.484 =-1486771.86 KJ/hr

69
3.2.2 Heat exchanger 1

70
 Flow rate Flow rate
Component C​p ∆H
Ibmole/hr mole/hr

Propane 2376.96 1077948.64 0.10584 3650882.69

Butane 534.7 242535.38 0.13367 1037430.53

Pentane 59.41 26948.37 0.167 144012.08

∑ 4832325.3 KJ/hr

71
3.2.3 Furnace

Stream temperature, T = 600 C and consider datum at 47 ˚C

Flow rate Flow rate ∆H

Component ∫C​p​dT
Ibmole/hr mole/hr KJ/hr

Propane 2376.43 1077948.64 69.62 75046784.32

Butane 534.69 242535.38 90.91 22048891.4

72
 Pentane 59.41 26948.37 112.17 3022798.66

∑ 100118475 KJ/hr

3.2.4 Energy balance for Heat Exchanger 2 (HE2)

73
Stream inlet at 600˚C datum at 25˚C
Flowrate ∫CpdT
Compound n∆H
(mol/hr) (kJ/mol)
H​2 2393.7 16.8053 40226.84661
C​3​H8​ 386.86 71.2935 27580.60341
C​3​H6​ 2376.4 59.5563 141529.5913
C​4​H1​ 0 1.9203 93.1652 178.9051336
C​4​H8​ 17.283 82.9306 1433.28956
C​5​H1​ 2 4.8009 114.9629 551.9253866
∑ 5180.9642 438.7138 211501.1614

Stream outlet at 1˚C datum at 25˚C

Flowrate ∫CpdT
Compound n∆H ∆Hv
(mol/hr) (kJ/mol)
H​2 2393.7 -0.6922 -1656.91914 -
C​3​H8​ 386.86 -2.5392 -982.314912 18.77
C​3​H6​ 2376.4 -2.8776 -6838.32864 18.42
C​4​H1​ 0 1.9203 -3.2082 -6.16070646 22.306
C​4​H8​ 17.283 -2.255 -38.973165 21.916
C​5​H1​ 2 4.8009 -4.008 -19.2420072 25.77
∑ 5180.9642 -15.5802 -9541.938571 107.182

Q = n(∆H​out​ - ∆H​in –​ (-∆Hv))

=5180.9642(-15.5802–438.7138-(-107.182))
​= -1798374.845 kJ/hr

74
75
3.2.5 Energy Balance for Flash Separator (S2)

Stream 5 (Feed Stream) at 1˚C datum at 25˚C

Flowrate ∫CpdT
Compound n∆H
(mol/hr) (kJ/mol)
H​2 2393.7 -0.6922 -1656.91914
C​3​H8​ 386.86 -2.5392 -982.314912
C​3​H6​ 2376.4 -2.8776 -6838.32864
C​4​H1​ 0 1.9203 -3.2082 -6.16070646
C​4​H8​ 17.283 -2.255 -38.973165
C​5​H1​ 2 4.8009 -4.008 -19.2420072
∑ 5180.9642 -15.5802 -9541.938571

Stream 6 (Distillate stream) at 1˚C datum at 25˚C

76
 Flowrate ∫CpdT
Compound n∆H
(mol/hr) (kJ/mol)
H​2 2393.7 -0.6922 -1656.91914

Stream 7 (Bottom stream) at 1˚C datum at 25˚C

Flowrate ∫CpdT
Compound n∆H
(mol/hr) (kJ/mol)
C​3​H​8 386.86 -2.5392 -982.314912
C​3​H​6 2376.4 -2.8776 -6838.32864
C​4​H1​ 0 1.9203 -3.2082 -6.16070646
C​4​H8​ 17.283 -2.255 -38.973165
C​5​H1​ 2 4.8009 -4.008 -19.2420072
∑ 2787.2642 -14.888 -7885.019431

There’s no heat transfer from the flash column:

Q = ΔH = 0

Q = n∆H​out​ - n∆H​in

=(-7885.019431+ (-1656.91914)) – (-9541.938571)

= 0 kJ/hr

77
78
3.2.6 Energy balance for heat exchanger 3

Stream inlet at 1˚C datum at 25˚C

Flowrate ∫CpdT
Compound n∆H
(mol/hr) (kJ/mol)
C​3​H​8 386.86 -2.5392 -982.314912
C​3​H​6 2376.4 -2.8776 -6838.32864
C​4​H1​ 0 1.9203 -3.2082 -6.16070646
C​4​H8​ 17.283 -2.255 -38.973165

79
 C​5​H​12 4.8009 -4.008 -19.2420072
∑ 2787.2642 -14.888 -7885.019431

Stream outlet at 42˚C datum at 25˚C

Flowrate ∫CpdT
Compound n∆H
(mol/hr) (kJ/mol)
C​3​H​8 386.86 1.2825 496.14795
C​3​H​6 2376.4 1.1118 2642.08152
C​4​H1​ 0 1.9203 1.7249 3.31232547
C​4​H8​ 17.283 1.5516 26.8163028
C​5​H1​ 2 4.8009 2.1421 10.28400789
∑ 2787.2642 7.8129 3178.642106

Q = n∆H​out​ - n∆H​in

= ​3178.642106– (-7885.019431)

= 63273.40588 kJ/hr

3.2.7 Energy Balance for Compressor (C1)

80
Inlet (stream 2)

Phase Vapor
Component Mixture
Pressure (bar) 1
Temperature (​o​C) 600
Total Molar Flow Rate (kmol/hr) 2349.64

Outlet (stream 3)

Phase Vapor
Component Mixture
Pressure (bar) 10
Temperature (​o​C) 600
Total Molar Flow Rate (kmol/hr) 2349.64

81
The outlet temperature of a stream by assuming the process is an ideal system.
P ( γ−1
γ )
T 2 = T 1( P 2 )
1

For ideal system, γ = 1.3.

Hence,
( 1.3−1
1.3 )
T 2 = 600( 10
1)

= 1020.75˚C

For energy balance,

ˆ − ∑n H
Q = ∆H = ∑ ni H ˆ
i i i
out in

T T
= ∑ ni ∫ C p dT − ∑ ni ∫ C p dT
out 298.15 in 298.15

Since there is no change component flow rate,

1293.9 1293.9 1293.9
Q = ∆H = ni [ ∫ 68.023×10−3 + 22.59×10−5 T − 13.11×10−8 T 2 + 31.71×10−12 T 3 dT + ∫ 59.58×10−3 + 17.71×10−5 T − 10.17×10−8 T 2 + 24.6×10−12 T 3 dT + ∫ 92.3×10−3 + 27.88×10−5
298.15 298.15 298.15
= 2349.64 (175.44 + 144.36 + 227 + 197.87 + 278.61 + 30.52 )

= 2476050.63 kJ/hr

82
3.2.8 Separation Unit 3 (S3)

83
For Stream 7
Liquid stream
Stream temperature, T = 315.15 K and consider datum at 298.15 K
Flow rate Flow rate ∫C​p​dT n∆H
Component C​p
(lbmol/hr) (mol/hr) (kJ/mol) kJ/hr

Propane 386.86 1.75447 х 10​5 0.10584 1.7993 315681.79

Butane 1.92 870.748 0.13367 2.2724 1978.69

Pentane 4.80 2176.871 0.167 2.8390 6180.14

Propene 2376.43 10.777 x 10​5 0.1199 2.0383 2196675.91

84
 Butene 17.28 7836.735 0.09396 1.5973 12517.62

∑ 2533034.15

For Stream 8
Gas stream
Stream temperature, T = 317.15 K and consider datum at 298.15 K

Flow rate Flow rate ∫C​p​dT n∆H

Component C​p
(lbmol/hr) (mol/hr) (kJ/mol) kJ/hr

Propane 386.86 1.75447 х 10​5 0.10584 2.0110 352823.92

Propene 2376.4 1077732.426 0.1199 2.2781 2.45518 х 10​6

2.8080 x 10​6
∑

For Stream 9

85
Liquid stream
Stream temperature, T = 381.55 K and consider datum at 298.15 K

Flow rate Flow rate ∫C​p​dT n∆H

Component C​p
(lbmol/hr) (mol/hr) (kJ/mol) kJ/hr

Butane 1.9203 870.884 0.13367 11.1481 9708.70

Butene 17.283 7838.095 0.09396 7.8363 61421.66

Pentane 4.80 2176.871 0.1670 13.9278 30319.02

∑ 101449.38

∑H = ​101449.38​+ ​2.8080 x 10​6 ​- ​2533034.15 ​= 376415.23kJ/hr

3.2.9 Separation Unit 4 (S4)

86
For Stream 8
Liquid stream
Stream temperature, T = 318.15 K and consider datum at 273.15 K

Flow rate Flow rate ∫C​p​dT n∆H

Component C​p
(lbmol/hr) (mol/hr) (kJ/mol) kJ/hr

87
 Propane 386.95 1.75517 х 10​5 0.10584 4.7628 8.35952 х 10​5

Propene 2376.43 10.77929 х 10​5 0.1199 5.3955 58.15965 х 10​5

66.51917 х 10​5
∑

For Stream 11
Gas stream
Stream temperature, T = 309.15 K and consider datum at 273.15 K

Flow rate Flow rate ∫C​p​dT n∆H

Component
lbmol/hr (mol/hr) (kJ/mol) (kJ/hr)

Propene 2376.43 10.77929 х 10​5 2.258 24.33963 х 10​5

88
 24.33963 х 10​5
∑

For Stream 12
Liquid stream
Stream temperature, T = 320.15 K and consider datum at 273.15 K

Flow rate Flow rate ∫C​p​dT n∆H

Component C​p
(lbmole/hr) (mol/hr) (kJ/mol) (kJ/hr)

Propane 386.95 1.75517 х 10​5 0.10584 4.97448 8.73105 х 10​5

8.73105 х 10​5
∑

Q = ∑H​ = 8.73105 х 10​5 ​+ 24.33963 х 10​5​- 66.51917 х 10​5​= -33.44849 х 10​5​ kJ/hr

89
3.2.10 Pump (P1)

Componen Molar Flow Rate Molar Flow Rate, F Molar Fv

t (lbmol/hr) (kmol/hr) volume,v(kmol/m​3​)
21.9375 3849.50
C​3​H​8 386.86 1.75476 х 10​2
23.2486 25055.8
C​3​H​6 2376 10.77734 х 10​2
0.09667 1
C​4​H​10 1.92 0.00870 х 10​2
0.09048 0.08410
C​4​H​8 17.28 0.07838 х 10​2
0.11452 0.70918
C​5​H​12 4.801 0.02178 х 10​2
0.24942
​∑Fv = 28906.35

90
Inlet Stream

Phase Liquid
Pressure (bar) 1
Temperature (​o​C) -47

Outlet Stream
Phase Liquid
Pressure (bar) 18
Temperature (​o​C) -47

Q = ​∑​Fv ( P)

Q = ​28906.35 х (18 -1) = ​4.91408 х 10​5​ kJ/hr

3.2.11 Energy Balance for Reactor

91
 1. C​3​H​8​ C​3​H​6​ + H​2 ˆ
∆H r1

2. C​4​H​10​ C​4​H​8​ + H​2 ˆ

∆H r2

ˆ
Q1 = nΔH = ∑ nĤ R1 + nĤ p1 + ∆H (for Propane)
r1

92
 ˆ + nH
Q2 = nΔH = n ∑ nH ˆ + ∆H
ˆ (for Butane)
R2 p2 r2

Q = Q1 + Q2

1. Energy balance for Propane

Component Ĥ R1 Ĥ p1 ∆Hˆ r1

Flow rate
1253192.74 2330911.57 -
(mol/hr)
Specific
Enthalpy, Ĥ -91.8 184.72 -
(kJ/mol)

93
 ∆H
-115043093.5 430565985.2 140.21
(kJ/hr)

∑ 315523031.9

2. Energy balance for Butane

Component Ĥ R2 Ĥ p2 ∆Hˆ r2

Flow rate
8708.84 16547.07 -
(mol/hr)
Specific
Enthalpy, Ĥ -119.0 240.61 -
(kJ/mol)
∆H
-1036351.96 3981390.5 125.87
(kJ/hr)

∑ 1945164.41

Q = Q1 + Q2

94
Q = 315523031.9 kJ kJ
hr + 1945164.41 hr

Q = 317.468 x 10​6​ kJ/hr

95
3.3 Simulation Result from ASPEN HYSYS
3.3.1 Material Balance

Mass
Stream no. (lbmole/hr)
(Hysys)
stream 1 3179
stream 2 3179
stream 3 769.4
stream 4 2410
stream 5 2523
stream 6 2523
stream 8 4692
stream 9 4692
stream 10 4692
stream 11 4692
stream 12 2533
stream 13 2159
stream 14 2533
stream 15 2533
stream 16 156.3
stream 17 2377
stream 23 2263
stream 24 113.4
stream 25 113.2

96
 3.3.2 Energy Balance

Energy, kJ/h
Equipment
(HYSYS)
Q-HE00 5.76E+06
Q-HE01 1.79E+08

97
 Q-HE02 1.65E+07
Q-Furnace 9.23E+07
Q-Compressor 6.78E+07
Q-Pump 6.90E+04

3.4 Percentage Difference between Manual Calculation and HYSYS Calculation

3.4.1 Mass Balance
Mass
Mass
(lbmole/hr
Stream no. (lbmole/hr) % Diff
)
(manual)
(Hysys)
stream 1 2971 3179 6.54
stream 2 2971 3179 6.54
stream 3 721.5 769.4 6.23
stream 4 2400.4 2410 0.40
stream 5 2787.3 2523 10.48
stream 6 2787.3 2523 10.48
stream 8 5181 4692 10.42
stream 9 5181 4692 10.42
stream 10 5181 4692 10.42
stream 11 5181 4692 10.42

98
 stream 12 2787 2533 10.03
stream 13 2393 2159 10.84
stream 14 2787 2533 10.03
stream 15 2787 2533 10.03
stream 16 165.4 156.3 5.82
stream 17 2663.5 2377 12.05
stream 23 2376.4 2263 5.01
stream 24 124.5 113.4 9.79
stream 25 124.5 113.2 9.98

3.4.2 Energy Balance

Energy, kJ/h Energy, kJ/h

Equipment % Diff
(manual) (HYSYS)
Q-HE00 4.83E+06 5.76E+06 16.09
Q-HE01 1.80E+06 1.79E+08 99.00
Q-HE02 6.33E+04 1.65E+07 99.62
Q-Furnace 1.00E+08 9.23E+07 8.46
Q-Compressor 2.48E+06 6.78E+07 96.35
Q-Pump 4.91E+05 6.90E+04 612.70

99
 CHAPTER 4

HEAT INTEGRATION

4.1 PROCESS ENERGY INTEGRATION

∆T​min​ = 10˚C

100
 Table 4.1:​ Steam Table Data

Stream Type T​supply (˚C)

​ T​target (˚C)
​ FCp (MW/K)

C1 Cold 20 50.08 0.053

C2 Cold 43.85 576.30 0.048

H1 Hot 870.7 -137.1 0.049

C3 Cold -136.8 30 0.028

∑FCp​C​ -∑FCp​H
T (˚C) ∆T (˚C) ∆Hi (MW) 1st Cascade
0.049 (​MW/K)

865.70 H1 0

284.4 -0.049 -13.9356

581.30 13.94

526.22 -0.001 -0.52622

55.08 14.46

6.23 0.052 0.32396

101
 48.85 C2 14.14
0.048 13.85 0.004 0.0554

35.00 14.08

10 0.032 0.3200

25.00 C1 13.76
0.053 156.8 -0.021 -3.2928

-131.80 C3 17.06
0.028 10.3 -0.049 -0.5047

-142.10 17.56

Figure 4.1:​ Algorithm Table

4.3 Heat Exchanger Network

∆H (MW) FCp(MW/K)

1.5942 0.053

50.08 20

25.5576 0.048

102
 576.3 43.85

4.6704 0.028

30 -136.8

49.3822 0.049

870.7 25.5576 1.5942 4.6704 17.56

Figure 4.2:​ Heat ExchangerNetwork

Table 4.2:​ Summary of Temperature of Heat Exchanger

T​H,in (˚C)
​ T​H,out​(˚C) T​C,in​ (˚C) T​C,out (˚C)
​

E1 870.7 349.12 43.85 576.3

E2 349.12 316.59 20 50.08
E3 316.59 221.28 -136.8 30
C 221.28 -137.1 - -

103
Figure 4.3:​ Process Flow
Diagram Heat Exchanger
Network
CHAPTER 5

OPTIMIZATION

Optimization is the tool to

maximize our profit by
minimizing the supply of
raw material and
maximizing the product. In
this case, our target that
we want to maximize it

104
the production of propene (100000 Ib/hr) and our supply that we want to minimize it is the propane which is initially set to 104800 Ib/hr depending on the
stoichiometric coefficient of (propane/propene =1.048) and (Hydrogen/propene= 0.0457).

Propane Propene Hydrogen

Ibmol 1 1 1

MW 44.1 42.08 2.16

+
Ib 44.1 42.08 2.16

Ib/Ib
1.048 1 0.0457
propene

USD RM/Ib 0.79 1.96 11.3

105
Step 1:
Define decision variables:
P1= amount of product (Propene)
P2=amount of byproduct (Hydrogen)
R=amount of reactant (Propane)
Z=maximum profit

Step 2:
Define objective function
Maximum profit (Z)​ ​= (1.96*P1 +11.3*P2)-(0.79*R)

Step 3:
Defining equality and inequality constraints:
a) Inequality constraints
Propane supply R << 104800 Ib/hr
Propene production P1>> 100000 Ib/hr

106
 b) Equality constraints
R= 1.048*P1
P2=0.0457*P1

c) Non-negativity constraint
R, P1, P2 ≥ 0

Step 4
Optimization technique
We used solver add-in in Microsoft excel:
P1=100000 Ib/hr
P2=4789.36 Ib/hr
R=104800 Ib/hr

107
 Z=167327.768 RM/hr
After optimization the maximum profit is close to the manually calculated one=​ RM 167327.768/hr.

CHAPTER 6

EQUIPMENT SIZING AND COSTING

6.1 Introduction

108
 In this chapter, the equipment sizing is done to all equipment that is involved in the proposed propylene production plant. Equipment sizing is a very important
aspect of process design as it enables the subsequent analysis that is involved in process design such as mechanical design and economy analysis. The sizing involves
the reactors, distillation column, compressor, pump, and heat exchangers.

6.2 Reactor

6.2.1 Sizing of Reactor

Parameter SI

Volumetric Flowrate , Q 3517.02 ft​3​/hr

Retention time (half-full), t 5 min

Reactor Volume, V 586.17 ft​3

Vessel Inside Diameter, D​i 7.20 ft

Vessel Length, L 14.4 ft

Design Type Vertical

Material of Contruction Low- Alloy Steel SA-387B

109
6.2.2 Costing of Reactor

Cost of vessel, Cv = ​$ 40, 279

Cost of ladders and nozzles, C​PL​ = ​$ 10, 264
Cost of purchase C​P​ = ​$ 58, 599
Total cost with bare-module = 4.16 (58, 599) = ​$ 243, 772

6.3 Pump
6.3.1 Sizing of Pump
Pressure inlet, P1 = 1000kPa = 145.04psi
Pressure outlet, P2 = 1750kPa = 253.82psi
Pressure drop, ΔP = 750kPa = 108.78psi
Volumetric flow rate, Q = 93.57 m​3​/hr = 413.09 gpm
ΔP
Pump head, H = ΔP (2.31)
SG
= ρ
​= 356.82 ft

110
6.3.2 Costing of Pump
Cost of pump, C​P​ = $ 6577.78
Cost of motor, C​P​ = $ 4689.90
Total cost with bare-module = (6577.78 + 4689.90) (3.30)
= ​$ 37,183.34

6.4 Distillation Column

6.4.1 Sizing and costing of the main vessel:

Parameters S1
Domed head wall
13.7 mm
thickness, a
Tray spacing, b 2ft

Column diameter, c 6.05 ft

Column wall thickness,

0.5 in
d

Design type Vertical

111
Material of Construction Carbon steel

Mineral
Material of insulation
wool,60mm

Column type Plate column

Plate type Sieve

Domed head type Torispherical

Costing in $:

Cost of vessel. Cv= $ 67436

Cost of ladders and nozzles, CPL= $ 21642
Cost of plates, CT= $ 27462

Total cost with bare-module

=4.16 (67436+21642+27462) = $ ​484809

112
6.4.2 Sizing and costing of the reflux drum:

Parameters S1
Domed head wall
13.7 mm
thickness,

Vessel length,L 8.924 ft

vessel diameter, D 17.85 ft

Column wall thickness,

0.562 in
d

Design type Vertical

Material of Construction Carbon steel

Mineral
Material of insulation
wool,60mm

After bare-model:
Cost= $ ​223290

113
6.4.3 Sizing and costing of the condenser:

Parameters S1

Length of tube 20 ft

Area of transfer,A​c 273.1 ft​2

Material of Construction Carbon steel

fixed head,
Type of HE shell tube
exchanger

Cp= $ 21721
After bare-module,
Cost= ​$ 68857

114
6.4.4 Sizing and costing of the re-boiler:

Parameters S1

Length of tube
20 ft

115
 Area of transfer,A​R 3.146 ft​2

Material of Construction Carbon steel

Type of HE kettle reboiler

CB= $ 65325
With bare-module
$ 3.17(65325) = ​$​ ​207080

Total cost for ​S1:

Vessel or Equipment Cost in $

main vessel 484809

the reflux drum 223290

the condenser 68857

the re-boiler 207080

Total 984036

116
6.5 Compresssor
6.5.1 Main Sizing Parameters

Parameters Compressor

Compressor Type Centrifugal

Drive Type Steam turbine

Material of Construction Stainless steel

Inlet Volumetric Flow Rate, Q​I 83283.83 ft​3​/min

117
 Inlet Pressure, P​I 14.5 psi

Outlet Pressure, P​O 72.52 psi

Specific Heat Ratio, ​k 1.10

6.5.2 Costing in $:

Purchase cost of compressor = ​$ 7,328,904

6.6 Heat Exchanger

6.6.1 Sizing of Heat exchanger (HE 2)

Heat exchanger type 2 shell and 4 tubes

Design type Fixed Head
Heat exchanger orientation Horizontal
Tube inlet direction Horizontal
Heat duty (kJ/s) 1594.2
Heat duty (Btu/hr) 5.44x10^6

Hot Cold
T​in​ (​˚​C) 870.7 43.85
T​out​ (​˚​C) 349.12 576.3

118
119
From Figure 18.15 (a), F​T​ = 0.85 and 2-4 exchanger is used.

U​i =
​ 235.5 Btu/​o​F.ft​2​.hr

Velocity of tube-side;

Cross section are/pass;

120
By using 0.75 in. O.D. 16 BWG tubing with I.D. of 0.62 in.;

Inside area/tube =
= 2.097x10​-3​ ft​2​/tube

Area per tube;

=
= 0.288 ft​2​/tube

L = 5.58 ft

121
6.6.2 Costing of Heat Exchanger (HE2)

F​BM​ = 3.17
0.5
F M = 1.08 + ( 86.34
100
)

= 2.01
2​
F​L =
​ 1.25 (Tube length = 5.58 ft​ )

2
F P = 0.9803 + 0.018 ( 145.04
100
) + 0.0017 ( 145.04
100
)

= 1.01

Fixed head:

C B = exp {11.0545 − 0.9228[ln(86.34)] + 0.09861[ln(86.34)]2 }

= $7,334.88

C P = (2.01)(1.25)(1.01)(7, 334.88)

= $18,613.18

Bare-module cost = 3.17 ( 18,613.18)

= ​$59,003
122
 CHAPTER 7

TOTAL CAPITAL INVESTMENT AND PAYBACK PERIOD

7.1 Total Capital Investment

By using method 3, which is based on the individual factors method of Guthrie, 1969, 1974 there are few steps to find the total capital investments, C​TCI​.

Firstly, we need to prepare an equipment list, giving the equipment tittle, label, size, material of construction, design temperature, and design pressure.

123
Equipment Label Size Material of Design Design Pressure Bare-module
Tittle Construction Temp. (bar) Cost, C​BM
(˚C)

Reactor R1 V=586.17 ft​3 Low- Alloy 576 1 $ 243, 772

Steel SA-387B
D​i =
​ 7.20 ft

L= 14.4 ft
Pump P1 H =356.82 ft Cast Steel -137.1 P​inlet​ = 10 $ 37,183
P​outlet =
​ 17.5

Distillation S1 D = 6.05 ft Carbon steel 50 15 ​$ 984,036

Column
t = 0.5 in

Compressor C1 Q = 83283.83 Carbon Steel 526 P​inlet ​= 1 $ 15,757,144

ft​3​/min
P​outlet​ = 10
Heat HE2 A = 86.34 ft​2 Carbon Steel 870.7 10 $ 59,003
Exchanger
C​TBM ∑
​ $17,081,138

124
 After we get the value of total bare module cost, C​TBM​, we need to find the site development cost, C​site​, building cost, C​buildings, and
​ offsite facilities cost, C​offsite
facilities​ by assuming some factor. The calculation of total capital investment cost is shown below:

Assume it is grass-roots plant, the value fo C​SITE​ is 10-20% of C​TBM​. Assume we take 15% of C​TBM​.
C​SITE​ = 0.15 (17,081,138)
C​SITE​ = $ 2,562,170.75

Assume it is process buildings, the value of C​BUILDINGS​ is 10% of C​TBM

C​BUILDINGS​ = 0.10 (17,081,138)
C​BUILDINGS​ = $ 1,708,113.80

The value of C​OFFSITE FACILITIES​ is 5% of C​TBM

C​OFFSITE FACILITIES​ = 0.05 (17,081,138)
C​OFFSITE​ ​FACILITIES​ = $ 854,056.90

Use factor of 1.18 to cover a contingency and a contractor fee

C​TPI​ = 1.18 ( C​TBM​ + C​SITE​ + C​BUILDINGS​ + C​OFFSITE​ ​FACILITIES​)
C​TPI​ = 1.18 (17,081,138+ 2,562,170.75 + 1,708,113.80 + 854,056.90)

125
C​TPI​ = $ 39,969863.01

The value of C​WC​ can be estimated 17.6% of C​TPI

C​WC​ ​= 0.176 (39,969863.01)
C​WC​ = $ 7,034,695.89

Thus,
C​TCI​ = ​C​TPI​ + C​WC
C​TCI​ = $ 39,969,863.01+ $ 7,034,695.89
C​TCI​ = $ 47,004,558.90

7.2 Payback Period

126
 Payback period is the time in which the initial cash outflow of an investment is expected to be recovered from the cash inflows generated by the investment. It
is one of the simplest investment appraisal techniques.

The formula to calculate payback period of a project depends on whether the cash flow per period from the project is even or uneven. In case they are even,
the formula to calculate payback period is:

Initial Investment
Payback Period =
Cash Inflow per Period
RM 152,764,816.40
= RM 167,327.77/hr

= 912.967 hr × 124day
hr
× 130month
days

= 1 month 9 days

127
 CONCLUSION

Propylene is one of the highest volume of chemicals produced globally and primarily used as an intermediate for the production of other chemical raw
materials. These chemical raw materials are then subsequently used to manufacture a large variety of substances and products. Example of such product is propylene,
a widely used plastic where the manufacturing process consumes more than half of the world’s production of polypropylene. There are other uses as well, such as
manufacture of acrylonitrile, oxo process chemicals, cumene, isopropanol, polygas chemicals, and propylene oxide. This shows that the production of propylene has
its demand in the global industry, hence a good marketability, especially in recent years where the price of propylene in the market ​is expected to continue rising as

128
the demand increases for the chemical material. Market research report says worldwide polypropylene capacity increased at a Compound Annual Growth Rate
(CAGR) of 5.2% from 2003, reaching 65 million tons per year (MMTY) in 2013, and is expected to continue rising to 86 MMTY by 2018, at a slightly higher CAGR
of 5.8%. As Malaysia is a part of the global market, it can be expected that prices in Malaysia to be affected by the global prices.

In terms of reaction pathways for this particular project, a screening process was done based on gross profit, economic potential as well as other factors related
such as energy consumption, toxicity, safety and environmental impacts. There are two reaction pathways suggested for the production of propylene, which are
dehydrogenation of propane, and metathesis reaction of ethylene and butene. From the screening process, it was shown that dehydrogenation of propane reaction is a
better process compared to the metathesis reaction. Based on the gross profit calculation, a dehydrogenation process would bring in a gross profit of RM 1.67/lb
propylene with 86% conversion compared to only RM 0.46/lb propylene for metathesis reaction with a 90% conversion yield. Since the calculation was based on
gross profit, further analysis need to be done in order to optimize the production process of propylene via the dehydrogenation of propane process for a sustainable
plant design.

In addition to the reaction pathways and process screening, a process synthesis for the production of propylene from dehydrogenation of propane was done by
following the steps that was introduced by Rudd, Powers, and Siirola. From these steps, a general overview of the whole process, starting from the raw materials into
products is translated into a process flow diagram, as well as the operating parameters were obtained. This is an important step in designing the production process of
our desired product before performing a further optimization of the processes and unit operations involved.

129
In a nutshell, after we had done a simulation, optimization and process integration, our total capital investment is $ 47,004,558.90.

130
 APPENDICES A

CALCULATION OF MATERIAL BALANCES

Sample Calculation for Mass Balance

1. Overall mass balance

Number of moles of propylene formed

= (100,000 lb/hr)/42.08

= 2376.43 lbmole/hr C​3​H​6

Assume 100% conversion, the mass flowrate of feed, m​1​ = 2376.43 x 44.1

131
 = 104800.56 lb/hr

for 86% conversion, the mass flowrate of recycle, R = (1-0.86)/0.86 x 104800.56

R = 17060.53 lb/hr

Mass flowrate of H​2 ​, m​3

= (no. of mole) X (molecular weight)

= (2376.43) x (2.01)

=​ 4776.62
​ lb/hr

Mass flowrate feed to the reactor, F = m​1​ + R

= 104800.56 + 17060.53 = 121861.09lb/hr

2. Separation Unit 1

Overall mass balance :

F​1​ = D​1​ + B​1

132
From the overall mass balance, we know that the mass flowrate of propane at D​1​ is 104800.56 lb/hr and the composition is assume 0.990 of C​3​H​8​, so

0.990 D​1 =
​ mass flow rate of C​3​H​8

D​1​ = mass flow rate of C​3​H​8​ / 0.990

= 104800.56 / 0.990

= 106263.1 lb/hr distillate

Propane balance :

0.8 F​1​ = 0.990 D​1

F​1​ = (0.990 x 106263.1)/0.8

F​1​ = 140163.6 lb/hr feed

F​1​ = D​1​ + B​1

B​1​ = 140163.6 – 106263.1

B​1​ = 33900.6 lb/hr of bottom product

133
3. Mixer

Overall mass balance :

F = D​1​ + R where R is the recycle of propane

from previous calculation, the value of D​1​ = 106263.1 lb/hr and R = 17060.53 lb/hr. Hence,

F = 106263.1 lb/hr + 17060.53 lb/hr = 123323.6 lb/hr

Propane balance : 0.990 x (106263.1) + 17060.53 x (1.0) = 123323.6 x (a​1​)

a​1​ = 0.991

Butane balance : 0.009 x (106263.1) = 123323.6 x (a​2​)

a​2​ = 0.007

and the weight percent of pentane

a​3 ​= 1 – 0.991 – 0.007 = 0.002

4. Reactor

For dehydrogenation of propane, 0.86% of propane is converted. The unreacted propane recycled.

134
(a) Mass flowrate of propane recycle

R = (1-0.86)/0.86 x 104800.56

R = 17060.53 lb/hr

(b) no of mol of propane recycle

= 17060.53/ 44.1 = 386.9 lbmole/hr

(c) no of mole of propene produce

= (121861.09 / 44.1) x 0.86 = 2376.64 lbmole/hr

(d) no of mole of butene produce

= 1116.106 / 58.12 x 0.9 = 17.28 lbmole/hr

(e) no of mole of hydrogen produce

= no of mole of hydrogen from propane + no of mole of hydrogen from propane

= 2376.4 + 17.28 = 2393.7 lbmole/hr

(f) mass flowrate of hydrogen produce

135
= 2393.7 x 2.01 = 4811.36 lb/hr

136
 APPENDICES B

CALCULATION OF ENERGY BALANCE

Sample Calculation for Energy Balance

Molar Flow Rate for Propane

1kgmol
n = 2763.3 lbmol
hr
x 2.205lbmol x 1000mol
1kgmol
= 1253197.28mol/hr

For reaction of propane

298K
H R1 = ∫ C p(reactant)dt
873K

298K
H R1 = ∫ (68.023×10−3 + 22.59×10−5 T − 13.11×10−8 T 2 + 31.71×10−12 T 3 )dt
873K

H R1 =− 91.81kJ/mol
298K
H R1 = ∫ C p(product)dt
873K

137
 873K
H p1 = ∫ (68.023×10−3 + 22.59×10−5 T − 13.11×10−8 T 2 + 31.71×10−12 T 3 )dt + (59.58×10−3 + 17.71×10−5 T − 10.17×10−8 T 2 + 24.6×10−12 T 3 ) dt + (28.84×10−3 + 0.00765×10−5 T + 0.3288
298K

H p1 = 91.79kJ/mol + 75.75kJ/mol + 17.18kJ/mol

H p1 = 184.72kJ/mol

ˆ = ∑ v ∆H
∆H ˆ = (1)(∆H
ˆ ) ˆ ˆ
r1 i f f C3H6 + (1)(∆H f )H2 − (1)(∆H f ) C3H8

ˆ = 20.41 kJ (−119.8)kJ
∆H r1 mol +0 − mol = 140.21 kJ/mol

138
APPENDICES C

ASPEN HYSYS

139
140
 APPENDICES D

CALCULATION OF HEAT INTEGRATION

Calculation for temperature of heat exchanger.

E1

Q=FCp​H​∆T

25.5576 = 0.049 (870.7-T)

T = 349.12˚C

Q=FCp​C​∆T

25.5576 = 0.048 (T – 43.85)

T = 576.3˚

141
E2

Q=FCp​H​∆T

1.5942 = 0.049 (349.12-T)

T = 316.59˚C

Q=FCp​C​∆T

1.5942 = 0.053 (T-20)

T = 50.08˚C

E3

Q=FCp​H​∆T

4.6704 = 0.049 (316.59-T)

T = 221.28˚C

142
Q=FCp​C​∆T

4.6704 = 0.028 (T—136.8)

T = 30˚C

143
 APPENDICES E

CALCULATION OF SIZING AND COSTING

REACTOR

Q = 3517.02 ft​3​/hr
Retention time =5 min at half full :
Volume, V = (3517.02 ft​3​/hr) × ( 5min ×1 hr ×2
60 min
) = 586.17 ft​3
Assume L/ D = 2
V = π (D/2)​2​L = ( π D​3​)/2

D = (2V/ π )​1/3​ = [2(586.17)/ π ]​ 1/3 ​= 7.20 ft

L= 2D = 14.4 ft

Operating Pressure = 1 bar = 14.5 psig :

P​d​ = exp { 0.60608 = 0.91615 [ln(14.5)] + 0.0015655 [ln(14.5)]​2​} = 21.48 psig (eqn. 22.61)
S = 10993.86 psi (low – alloy)

144
E = 1.0
21.48 × 7.2 ×12
t​P =
​ 2 (10993.86)(1.0) − 1.2 (21.48)
= 0.085 in

Minimum wall thickness, t​P =

​ 0.375 in

t​S​ = t​P ​+​ ​t​C ​= 0.375 + 0.125 = 0.5 in

W = 3.14 [ 7.2 + 0.0417) (14.4 + 0.8 (7.2)] 0.0417 (490) = 9366.83 lb
Cv = exp { 7.0132 + 0.18255[ ln (9366.83) ] + 0.02297 [ ln (9366.83)]​2​} = $ 40, 279
​
C​PL​ = 361.8 ( 7.2 ) 0.73960​ ​
(14.4) 0.70684​ = $ 10, 264
Cp = F​M​Cv + C​PL =
​ 1.2 (40, 279) + 10, 264 = $ 58, 599

Bare-Module cost
= 4.16 ( 58, 599 ) = $ 243, 772

PUMP
Pressure inlet, P1 = 1000kPa = 145.04psi

Pressure outlet, P2 = 1750kPa = 253.82psi

Pressure drop, ΔP = 750kPa = 108.78psi

Q = 93.57 m​3​/hr = 413.09 gpm

145
 ΔP (2.31) ΔP 1lb/in2 f t3 144 in2
H= SG
= ρ
= 108.78 psi x 1 psi
x 43.9 lb
x 1 f t2

H = 356.82 ft

S = Q (H)​0.5​ = 413.09(356.82)​0.5​ = 7803.14 gallon.ft​0.5​/min

ln S = 8.962

C​B​ = exp [9.7171 - 0.6019(8.962) + 0.0519(8.962)​2​] = $ 4872.43

F​T​ = 1, F​M​ = 1.35 (Assume cast steel)

C​P​ = F​T​F​M​C​B​ = (1)(1.35)(4872.43) = $ 6577.78 for pump

Q Hρ gal 43.9 lb 0.1334f t3 1

P​T​ = 33000
= 413.09 min
x 356.82 ft x f t3
x 1 gal
x 33000

lb.f t
= 26.16 min

ln Q = 6.024

ηp = -0.316 +0.24015 (6.024) – 0.01199(6.024)​2

= 0.6956
PT 26.16 lb.f t
P​B​ = ηp
= 0.6956
= 37.61 min

ln P​B​ = 3.627

146
η​m​ = 0.80 + 0.0319(3.627) – 0.00182(3.627)​2
= 0.892
PT 26.16 lb.f t
P​C​ = ηpηm
= (0.6956)(0.892)
= 42.16 min

ln Pc = 3.741
C​B​ = exp [5.8259+0.13141(3.741)+ 0.053255 (3.741)​2​ + 0.028628 (3.741)​3​ –​ 0.0035549(3.741)​4​]
= $ 2605.50
FT = 1.8 (assume explosion-prof enclosure)
C​P​ = F​T​C​B =
​ 1.8(2605.50) = $ 4689.9 for motor

F​BM​ = 3.30
C​PTotal​ (Pump + Motor) = (6577.78 + 4689.9) (3.30)
= $ 37,183.34

DISTILLATION COLUMN
Distillation column, S1
Main vessel sizing

Diameter, D​T
F​LG​= 0.1345

147
C​SB​=0.34
F​ST​=0.757
Assume:
F​F​=1,F​HA​=1
C=0.2574
U​f​=2.758 ft/s
A​d​/A​T​=0.10378
Assume 80% flooding
4( 425100 )
DT= 0.8(2.758)(3.14)(1−0.10378)(2.09)
3600
=6.05 ft=1.844 m

Purchase costs of the vessel

P0=1500 Kpa=217.55 psig

Pd= 5.582 psig
Di=6.05 ft
L= 50 ft
(5.582)(6.05)(12)
tp= 2(15000)(0.85)−(1.2*5.582)
=0.0158 < tabulated data thus t​p​=0.375 in

148
t​s​=0.375+0.125=0.5 in
W= π (Di+ts) (L+0.8Di) ts ρ= 21458 Ib
C​v​= $ 67436
C​PL​= 300.9 * 6.050.63316 500.8016 = $21642
CT= $ 27462

Total cost after bare-module= 4.16(27462+21642+67436)= ​$ 484806

Cost of the reflux drum

Dvolumetric =3350
Volume flow = (1+3) *(3350) = 13400 ft​3​/hr
Assume residence time of 5 mins at full capacity and L/D=2
V=13400 ft​3​/hr * (5 min/ (60 min/hr))
V=116 ft​3
D=8.924 ft​3
L=17.85 ft​3

149
tp =7/16=0.4375 in
t​s =0.4375+0.125=0.562
​ in
W=π (D​i​ + t​s​)*(L+0.8*D​i​)*(t​s​)*ρ
W=16150 Ib
C​v​= $ 733210
After bare-model:
Cost= $ ​223290

Condenser

Qc= -0.126* 105

U​f​=4.402 Btu/ (ft​2​*hr*F)
T​LM​= 10.48 F
Ac=273.1 ft​2

Assume fixed head, shell tube exchanger and carbon steel, 20 feet long:

150
F​L​=1
F​P​=1
T​M​=2.732
C​B​= 7950

Cp= $ 21721
After bare-module,
Cost= ​$ 68857

Re-boiler costing

Heat flux 5000 Btu/hr.ft3

Q=16600 Kj/hr=15733.76 Btu/hr
A​R​=QR/ Flux
A​R​=3.146 ft2
Choose kettle reboiler with carbon steel, 20 ft long
F​L​=F​M​=F​P​=1

151
CB= $ 65325
With bare-module
$ 3.17(65325) = ​$​ ​207080

COMPRESSOR
(a) Preliminary estimate of brake horsepower, P​B

3​
Inlet volumetric flow rate, Q​I =
​ 83,283.83 ft​ /min

Inlet pressure, P​I = 14.5 psi

Outlet pressure, P​O = 72.52 psi
Specific heat ratio, ​k = 1.10
Mechanical efficiency, η​B = 0.4952

1.10−1
1.10
P B = 0.00436×( 1.10−1 )× 83283.83×14.5
0.4952
×(( 72.52
14.5
) 1.10
− 1) = 18430.94 BHp

(b) Purchase cost of compressor

152
Assumption:
Drive efficiency, η​C = 0.75
Material factor, F​M = 1.00 (carbon steel)
Drive type factor, F​D = 1.15 (steam turbine)

18430.94
PC = 0.75
= 24574.59 Hp

Base purchase cost,

C B = exp{7.5800 + 0.80[ln (P C ) ]}

C B = exp{7.5800 + 0.80[ln (24574.59) ]}

C B = $ 6, 372, 960

Total purchase cost,

CP = F DF M CB

C P = 1.15×1.00×$ 6, 372, 960

C P = $ 7, 328, 904

153
HEAT EXCHANGER (HE2)
Sizing of Heat exchanger (HE 2)

Heat exchanger type 2 shell and 4 tubes

Design type Fixed Head
Heat exchanger orientation Horizontal
Tube inlet direction Horizontal
Heat duty (kJ/s) 1594.2
Heat duty (Btu/hr) 5.44x10^6

Hot Cold
T​in​ (˚C) 870.7 43.85
T​out​ (˚C) 349.12 576.3 154
From Figure 18.15 (a), F​T​ = 0.85 and 2-4 exchanger is used.

155
U​i =
​ 235.5 Btu/​o​F.ft​2​.hr

Velocity of tube-side;

Cross section are/pass;

156
By using 0.75 in. O.D. 16 BWG tubing with I.D. of 0.62 in.;

Inside area/tube =
= 2.097x10​-3​ ft​2​/tube

Area per tube;

=
= 0.288 ft​2​/tube

L = 5.58 ft

Costing of Heat Exchanger (HE2)

157
F​BM​ = 3.17
0.5
F M = 1.08 + ( 86.34
100
)

= 2.01
2​
F​L =
​ 1.25 (Tube length = 5.58 ft​ )

2
F P = 0.9803 + 0.018 ( 145.04
100
) + 0.0017 ( 145.04
100
)

= 1.01

Fixed head:

C B = exp {11.0545 − 0.9228[ln(86.34)] + 0.09861[ln(86.34)]2 }

= $7,334.88

C P = (2.01)(1.25)(1.01)(7, 334.88)

= $18,613.18

Bare-module cost = 3.17 ( 18,613.18)

= ​$59,003

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