TITLE: PRODUCTION OF 80,000 MT/YR OF BENZENE, TOLUENE AND XYLENE (BTX) FROM PYGAS

1.1 Process Flow Diagram

1.2 Stream data
Table 1 Comparison on Material Balance

Units Mass Flows Units Mass Flows

(kg/hr) (kg/hr)
PYGAS 19097.2 S20 1405.7
S1 19097.2 TOLUENE 2774.5
S2 19097.2 S21 1405.7
H2 477.4 S22 1405.7
S3 477.4 S23 355.2
S4 2427.7 S24 355.2
S5 2167.0 S25 3.0
S8 216.7 S26 10348.8
S9 19358.0 S27 2801.3
S10 19358.0 XYLENE 355.2
S11 19358.0 SOLVENT 3.0
S12 5949.6 S29 16420.5
S13 5949.6 S28 2801.3
S14 13408.4 S30 6073.0
S15 8873.0 S31 10347.5
S16 4535.4 S32 10347.5
S17 2774.5 BENZENE 6073.0
S18 1760.9 S6 1950.3
S19 1760.9 S7 216.7

Table 2 Comparison on Energy Balances

Unit Operation (kW) Simulation (kW) Manual (kW) Error %
Pump, P-101 37.8 50.4 25.0
Pump, P-102 0.9 0.8 11.1
Heater, E-101 779.4 597.8 23.3
Cooler-E-102 -1215.2 -1249.5 2.7
Cooler-E-103 -615.3 -859.6 28.4
Cooler, E-104 -676.2 -692.6 2.4
Cooler, E-105 -368.1 -373.2 1.4
Cooler, E-106 -960.0 -844.5 12.0
Cooler, E-107 -0.07 -0.06 14.3
Cooler, E-108 -118.0 -112.4 4.7
Cooler, E-109 -156.6 -180 4.7
Cooler, E-110 -150.2 -131.5 12.5
Cooler, E-111 -38.0 -49.4 23.1
Compressor, C-101 1358.2 1518.2 10.5
Reactor, R-101 -6229.7 -8348.9 25.4
Distillation Column, T-101
Condenser -2132.3 -2167.8 1.6
 Reboiler 2611.17 2643.6 1.2
Distillation Column, T-102
Condenser -3344.5 -3313.0 0.9
Reboiler 3719.3 3701.1 0.5
Distillation Column, T-103
Condenser -1950.9 -1013.4 19.9
Reboiler 1962.0 1082.6 21.9
Distillation Column, T-104
Condenser -5815.4 -5440.8 1.2
Reboiler 5731.0 5589.1 5.1
Extractive Distillation Column, T-105
Condenser -1013.27 -1132.9 11.8
Reboiler 1630.0 1803.7 10.7
Stripper, T-106
Reboiler 3890.4 4208.66 3.6

1.3 Raw material and product prices

Table 3 Prices of raw material
Component Price (RM) References
Pyrolysis Gasoline 3772.048 (Price trend market, 2017)
Hydrogen 25940.53 (IHS.com,2015)

Table 4 Price Data for Product

Component Price (RM/MT) References
Benzene 4042.06 (SunSirs, 2017)
Toluene 3477.73 (SunSirs, 2017)
Xylene 3490.11 (SunSirs, 2017)

1.4 Equipment Specifications

R-101
REACTOR
Item: Reactor
Code: R-101
Equipment Reactor
Tag no. R-101
Type of reactor Trickle bed reactor
Function To hydrogenate the pyrolysis gasoline
components
Operation Continuous
Operating Pressure 33 bar
Operating Temperature 373 K, isothermal
 Reactor Design
Diameter 2.6 m
Length 7.8 m
Volume 34.0 m3
Catalyst Nickel supported on alumina
Catalyst form Solid
Catalyst density 750 kg/m3
Catalyst weight 8469 kg
Mechanical Design
Design pressure 36.3 bar
Design temperature 383 K
Material of construction Stainless steel 316
Wall thickness 32.5 mm
Outer diameter 2.67 m
Type of head Ellipsoidal head
Head thickness 32.2 mm
Weight of Reactor 249.9 kN
Total Weight 333.0 kN
Cooling jacket design
Fluid handled Cooling water
Jacket area 71.03 m2
Heat removal by jacket 8348.9 kW

T-101
Distillation Column, T-101
Item: Distillation column Date:
Code: T-101 By: Nor Izzati Munirah Binti Rozaidi
Function To separate C5 and lighter components
Specification
Design Vertical
Material of construction Carbon steel
Component Distribution
Number of stages 30
Reflux ratio 4.2
Location of feed stage 16
Column Sizing
Tray spacing 0.5 m
Flooding velocity 0.05 m/s
Net area 5.1 m2
Downcomer area 0.8 m2
Column diameter 2.7 m
Column height 20.0 m
Plate Hydraulic Design
 Active area 3.6 m2
Hole area 0.2 m2
Tray thickness 5 mm
Type of tray Sieve tray
Hole diameter 5 mm
Perforated area 3.3 m2
Total column pressure drop 151.8 mm liquid
Flow Pattern
Liquid Flow Pattern Single pass
Maximum volumetric flow rate 0.006 m3/s
Weir Design
Weir Length 2.10 m
Weir Height 0.05 m
Maximum liquid crest 18.4 mm liquid
Minimum liquid crest 14.5 mm liquid
Weep Point
Minimum vapour velocity 7.1 m/s
Actual vapour velocity 12.8 m/s
Downcomer Liquid Backup
Downcomer apron area 0.07 m2
Residence time 16.6 s
Entrainment
Percent flooding 80 %
Liquid-vapour flow factor 0.05 m/s
Fractional entrainment 0.06
Hole Design
Angle subtended by edge of plate 81°
Hole diameter 5 mm
Number of holes 10905 holes
Mechanical Design
Column wall thickness 12 mm
Type of head Torispherical head
Head thickness 12 mm
Type of insulation Mineral wool
Insulation thickness 75 mm
Type of vessel support Conical skirt
Skirt thickness 20 mm
Corrosion allowance 10 mm

T-102
Distillation Column, T-102
Item: Distillation column
Code: T-102
Function To separate benzene, cyclohexane and
cyclohexene from others components
Specification
Design Vertical
Material of construction Carbon steel
Component Distribution
Number of stages 23
Reflux ratio 1.5
Location of feed stage 18
Column Sizing
Tray spacing 0.6 m
Flooding velocity 0.04 m/s
Net area 4.2 m2
Downcomer area 0.6 m2
Column diameter 2.5 m
Column height 18.7 m
Plate Hydraulic Design
Active area 3.0 m2
Hole area 0.2 m2
Tray thickness 5 mm
Type of tray Sieve tray
Hole diameter 5 mm
Perforated area 2.7 m2
Total column pressure drop 143.9 mm liquid
Flow Pattern
Liquid Flow Pattern Single pass
Maximum volumetric flow rate 0.003 m3/s
Weir Design
Weir Length 1.90 m
Weir Height 0.05 m
Maximum liquid crest 18.0 mm liquid
Minimum liquid crest 14.2 mm liquid
Weep Point
Minimum vapour velocity 7.2 m/s
Actual vapour velocity 12.2 m/s
Downcomer Liquid Backup
Downcomer apron area 0.06 m2
Residence time 17.9 s
Entrainment
Percent flooding 80 %
Liquid-vapour flow factor 0.04 m/s
Fractional entrainment 0.07
Hole Design
Angle subtended by edge of plate 81°
Hole diameter 5 mm
Number of holes 9083 holes
 Mechanical Design
Column wall thickness 12 mm
Type of head Torispherical head
Head thickness 12 mm
Type of insulation Mineral wool
Insulation thickness 75 mm
Type of vessel support Conical skirt
Skirt thickness 20 mm
Corrosion allowance 10 mm

T-103
Distillation Column, T-103
Item: Distillation column
Code: T-103
Function To separate toluene from other components
Specification
Design Vertical
Material of construction Carbon steel
Component Distribution
Number of stages 31
Reflux ratio 0.89
Location of feed stage 21
Column sizing
Tray spacing 0.5 m
Flooding velocity 0.08 m/s
Net area 6.0 m2
Downcomer area 0.9 m2
Column diameter 3.0 m
Stack height 15.0 m
Column height 20.5 m
Plate Hydraulic Design
Active area 4.2 m2
Hole area 0.3 m2
Tray thickness 5 mm
Type of tray Sieve tray
Hole diameter 5 mm
Perforated area 3.9 m2
Total column pressure drop 82.2 mm liquid
Flow Pattern
Liquid Flow Pattern Reverse flow
Maximum volumetric flow rate 0.002 m3/s
Weir Design
 Weir Length 2.3 m
Weir Height 0.05 m
Maximum liquid crest 17.2 mm liquid
Minimum liquid crest 13.5 mm liquid
Weep Point
Minimum vapour velocity 7.8 m/s
Actual vapour velocity 4.8 m/s
Downcomer Liquid Backup
Downcomer apron area 0.07 m2
Residence time 15.2 s
Entrainment
Percent flooding 89 %
Liquid-vapour flow factor 0.08 m/s
Fractional entrainment 0.05
Hole Design
Angle subtended by edge of plate 81°
Hole diameter 5 mm
Number of holes 12838 holes
Mechanical Design
Column wall thickness 12 mm
Type of head Torispherical head
Head thickness 12 mm
Type of insulation Mineral wool
Insulation thickness 75 mm
Type of vessel support Conical skirt
Skirt thickness 20 mm
Corrosion allowance 10 mm

T-104
Distillation Column, T-104
Item: Distillation column
Code: T-104
Function To separate xylene from other components
Specification
Design Vertical
Material of construction Carbon steel
Component Distribution
Number of stages 22
Reflux ratio 0.56
Location of feed stage 16
Column sizing
Tray spacing 0.6 m
Flooding velocity 0.07 m/s
Net area 4.3 m2
Downcomer area 0.6 m2
Column diameter 2.50 m
Stack height 12.6 m
Column height 18.0 m
Plate Hydraulic Design
Active area 13.0 m2
Hole area 0.2 m2
Tray thickness 5 mm
Type of tray Sieve tray
Hole diameter 5 mm
Perforated area 2.8 m2
Total column pressure drop 82.9 mm liquid
Flow Pattern
Liquid Flow Pattern Reverse flow
Maximum volumetric flow rate 0.001 m3/s
Weir Design
Weir Length 1.9 m
Weir Height 0.05 m
Maximum liquid crest 14.6 mm liquid
Minimum liquid crest 11.5 mm liquid
Weep Point
Minimum vapour velocity 7.1 m/s
Actual vapour velocity 5.5 m/s
Downcomer Liquid Backup
Downcomer apron area 0.06 m2
Residence time 16.4 s
Entrainment
Percent flooding 80 %
Liquid-vapour flow factor 0.07 m/s
Fractional entrainment 0.04
Hole Design
Angle subtended by edge of plate 81°
Hole diameter 5 mm
Number of holes 9127 holes
Mechanical Design
Column wall thickness 18 mm
Type of head Torispherical head
Head thickness 18 mm
Type of insulation Mineral wool
Insulation thickness 75 mm
Type of vessel support Conical skirt
Skirt thickness 20 mm
Corrosion allowance 10 mm
T-106
Stripper, T-106
Item: Stripper Date:
Code: T-106 By: Nor Izzati Munirah Binti Rozaidi
Function To separate benzene from solvent
Specification
Design Vertical
Material of construction Carbon steel
Component Distribution
Number of stages 6
Reflux ratio 0.58
Location of feed stage 4
Column Sizing
Tray spacing 0.6 m
Flooding velocity 0.08 m/s
Net area 0.7 m2
Downcomer area 0.1 m2
Column diameter 1.0 m
Column height 5.6 m
Plate Hydraulic Design
Active area 0.5 m2
Hole area 0.03 m2
Tray thickness 5 mm
Type of tray Sieve tray
Hole diameter 5 mm
Perforated area 0.5 m2
Total column pressure drop 631.1 mm liquid
Flow Pattern
Liquid Flow Pattern Single pass
Maximum volumetric flow rate 0.005 m3/s
Weir Design
Weir Length 0.76 m
Weir Height 0.05 m
Maximum liquid crest 31.7 mm liquid
Minimum liquid crest 25.0 mm liquid
Weep Point
Minimum vapor velocity 7.4 m/s
Actual vapor velocity 36.9 m/s
Downcomer Liquid Backup
Downcomer apron area 0.02 m2
Residence time 11.3 s
Entrainment
Percent flooding 80 %
Liquid-vapour flow factor 0.08 m/s
Fractional entrainment 0.04
 Hole Design
Angle subtended by edge of plate 84°
Hole diameter 5 mm
Number of holes 1536 holes
Mechanical Design
Column wall thickness 12 mm
Type of head Torispherical head
Head thickness 12 mm
Type of insulation Mineral wool
Insulation thickness 75 mm
Type of vessel support Conical skirt
Skirt thickness 20 mm
Corrosion allowance 10 mm

T-105
Extractive Distillation Column, T-105
Item: Extractive distillation Date:
column By: Nur Eliza Binti Badrul Hisham
Code: T-105
Function To separate cyclohexane from benzene and solvent
Specification
Design Vertical
Material of Construction Carbon steel
Operating Condition
Residence Time 99 seconds
Temperature 74 - 109 °C
Pressure 1 bar
Packing Design
Number of stages 18
Type of column Packed column
Type of packing Random packing (Pall Rings)
Size of packing 1 in
Surface area 207 m2/m3
Packing factor 184 m-1
Packing support Stacked packing
Fluid Flow
Min wetting rate 0.00002 m3/s.m2
Actual wetting rate 0.00008 m3/s.m2
Liquid hold-up 0.11 m3/m3
Flooding pressure drop 50 mm H2O/m height of packing
Column Design
HETP 0.4572 m
Diameter 1.0 m
Height 8.0 m
Volume 10.0 m3
 E-101 –E-110

Heater Cooler Cooler Cooler Cooler Cooler Cooler Cooler Cooler Cooler
Item (No)
(E-101) (E-102) (E-103) (E-104) (E-105) (E-106) (E-107) (E-108) (E-109) (E-110)
The cooler
The heater The cooler The cooler The cooler The cooler The cooler The cooler The cooler The cooler
E-102 is
E-101 is E-103 is E-104 is E-105 is E-106 is E-107 is E-108 is E-109 is E-110 is
used to
used to used to used to used to used to cold used to used to used to used to
cold down
heat up the cold down cold down cold down down the cold down cold down cold down cold down
the process
Function process the process the process the process process the process the process the process the process
mixture at
mixture at mixture at mixture at mixture at mixture at 1 mixture at mixture at mixture at mixture at
33 bar
33 bar 1 bar from 1 bar from 1 bar from bar from 1 bar from 1 bar from 1 bar from 1 bar from
from
from 82℃ 53℃ to 36℃ to 78℃ to 253℃ to 101℃ to 80℃ to 197℃ to 210℃ to
345℃ to
to 100℃ 49℃ 30℃ 30℃ 77℃ 30℃ 30℃ 30℃ 30℃
100℃
Horizontal shell and tube
Type
Split-ring floating head
Duty (kW) 200.3 2611.1 36.2 679.9 157.3 917.9 118.8 143.7 151.7 38.8
Overall
coefficient (𝑊/ 300 150 300 300 300 300 300 300 300 300
𝑚2 . 𝐾)
Tube Side
Fluid handled Steam Process Mixture
Flow rate (kg/hr) 19230.7 2391.3 18926.3 5793.1 5803.4 9871.4 2697.6 2827.3 1365.81 344.49
Temperature in
115 345 52 36 78 253 101 80 197 210
(℃)
Temperature out
105 100 49 30 30 77 30 30 30 30
(℃)
Pressure (Bar) 1 33 1
Material Carbon steel
Tubes
Outside Diameter
19.1 19.1 19.1 19.1 25.4 25.4 25.4 25.4 25.4 19.1
(mm)
Length (m) 1.83 2.44 1.83 1.83 1.83 2.44 2.44 2.44 1.83 2.44
Pitch (mm) 23.8
Arrangement Square
Tubes per pass 2 2 2 2 4 2 4 4 4 2
Number of passed 144 284 15 32 72 135 35 31 29 13
Shell-side
Process
Fluid handled Cooling Water
mixture
Flow rate (kg/hr) 190001.7 17102.0 1598.1 3264.7 5094.7 10121 3517.2 2149.0 1955.3 604.7
Temperature in
82 25 25 25 25 25 25 25 25 25
(℃)
Temperature out
100 90 35 30 50 100 50 52 80 70
(℃)
Pressure (Bar) 33 1 1 1 1 1 1 1 1 1
Material Carbon steel
Shell
Diameter (m) 0.65 0.77 0.26 0.33 0.76 0.76 0.60 0.55 0.55 0.25
Baffle spacing
0.42 0.15 0.05 0.07 0.03 0.15 0.11 0.10 0.10 0.04
(m)
Number of shell 1 1 1 1 1 1 1 1 1 1
Manufacturer HX Thermal Solution Sdn Bhd
S-101 – S-106

Type of
Vertical cylinder Spherical
storage
Item number S-101 S-102 S-103 S-104 S-105 S-106

Function To store To store To store To store

To store pygas To store hydrogen
benzene toluene xylene gasoline pool

Specification

Material of
Carbon steel Stainless steel
construction
Inventory
7 7 7 7 7 7
(days)
Volume (m3) 186.6 186.6 19.6 419.8 477.8 226

Height (m) 9.5 9.5 4 9.5 9.5 -

Diameter (m) 5 5 2.5 7.5 8 8

No of tanks 4 3 2 5 8 3
M-102
Mixer, M-102
Item : Mixer
Item No. : M-102
No. of required :1
Function : To mix the recycled solvent with the fresh solvent.
Operation : Continuous
Mixer Specification
Operating
: 77.0
temperature (℃)
Operating
: 1.0
pressure (bar)
Length (m) : 1.2
Diameter (m) : 1.2
3 : 1.38
Volume (m )
Material of
: Stainless Steel (316)
construction
Power (kW) : 16.4

C-101 A/B
Compressor, C-101A/B
Item : Compressor
Item No. : C-101A/B
No. of required :1
Function : To compress the hydrogen gas from 1 bar (14.5 psia) to 33 bar
(478.0 psia).
Operation: : Continuous
Type : Reciprocating piston compressor
Compressor Specification
Flow rate : 4.5
(MMSCFD)
Pressure inlet
: 14.5
(psia)
Pressure outlet
: 478.0
(psia)
Temperature inlet
: 536.0
(Ro)
Temperature
: 560.0
outlet (Ro)
Material : Stainless Steel (316)
Power (kW) : 26.0
Efficiency (%) : 90.0
P-101 – P-105
Identification P-101 P-102 P-103 P-104 P-105
No.
Function To maintain the To maintain
To maintain To maintain To
flow pressure of the flow
the flow the flow
maintain
the pyrolysis pressure of
pressure of pressure of
gasoline from the pyrolysis
the the the
the storage tank gasoline from
pyrolysis pyrolysis
pressure at
gasoline
the storage gasoline
to the process
from from 5 barg
tank to the
plant the storage the storage
from the
process plant
tank to the tank to the
bottom of
process process
T-103 to
plant plant
the inlet of
T-105

Number of
1 1 1 1 1
required pump
Operating
condition 10 bar 10 bar 10 bar 3 bar 5 bar
Discharge
pressure
Design sizing
Mass flowrate 19097.22 kg/hr 19097.22 19097.22 19097.22 13408
Efficiency 63% kg/hr 63% kg/hr 63% kg/hr 63% kg/hr
Power 10.03 kW 10.03 kW 10.03 kW 3.01 kW 30%
consumption 1.07 kW
1.5 Utilities

Cooling Water

Equipment Water Flow Rates (kg/hr)

E-102 (Cooler) 1,820
E-103 (Cooler) 10,417
E-104 (Cooler) 38,985
E-105 (Cooler) 6,690
E-106 (Cooler) 1,285
E-108 (Cooler) 165
E-109 (Cooler) 2,843
E-110 (Cooler) 201
E-111 (Cooler) 52
T-101 (Condenser) 374,096
T-102 (Condenser) 373,646
T-103 (Condenser) 245,992
T-104 (Condenser) 70,741
T-105 (Condenser) 491,597
T-106 (Condenser) 2,232,417
TOTAL 3,850,947
Steam

Steam Utilities Cost

Types of Steam Cost
Low pressure (5 barg, 160°C) $27.70/1000kg
Medium pressure (10 barg, 184°C) $28.31/1000kg
High pressure (41 barg, 254°C) $29.97/1000kg

Summary of steam consumption used by equipment

Equipment Heat Duty (kW) Type of Steam
E-101 2000.30 High pressure steam
RB-101 2,611.17 Low pressure steam
RB-102 3,719.31 Low pressure steam
RB-104 5,589.07 Low pressure steam
RB-105 1,630.03 Low pressure steam
RB-106 4,208.66 Low pressure steam

Electricity
Pump/Compressor Electric cost
(RM/kW.h)
P-101 0.337
P-102 0.337
P-103 0.337
P-104 0.337
P-105 0.337
C-101 0.337