Kuwait University Fall 2014/2015

Dept. of Chemical Engineering

ChE 391 – Process Synthesis

Dec. 17, 2014 Simulation Exam Time: 60 minutes

Name: Good Luck ID:

CUMENE PLANT

As shown in the figure below, cumene (C 6 H 5 C3 H 7 ¿ is produced be reacting benzene with

propylene. The raw materials are mixed with recycle propylene before entering the reactor.
In the reactor, the reaction is:
C 6 H 6 +C 3 H 6 → C6 H 5 C 3 H 7
The reactor is adiabatic and the vapor effluent from the reactor is cooled and feed to the
first distillation column. All of the propylene will be removed as overhead product from the
column and then it will be heated and recycled. The bottom product of the column includes
cumene and unreacted benzene which are fed to a second distillation to purify the cumene.

Use "SRK" as a fluid package to simulate the process using or identifying at least four
different heuristics from the list at the last page. Save the file on both a CD and the
"Desktop", using a file name that indicates your name and ID, for example "Ali 20221111".
It is your responsibility to make sure that all files are included in the CD, which should be
submitted together with this exam paper with your name written above, before leaving the
room.

1
Input data and desired final results are given as follow:
Feed Stream:
Benzene Propylene
Flow rate (kmole/hr) 40 40
Temperature (oC) 25 25
Pressure (kPa) 101.325 101.325
Benzene heater: Outlet temperature = 105oC
Propylene heater: Outlet temperature = 105oC
Reactor feed compressor: outlet pressure = 350 kPa
Reactor: Conversion: 90 percent conversion of Benzene
Pressure drop = 100 kPa
Product cooler: outlet temperature = 55oC
Distillation unit 1: Number of theoretical stages 10
Reflux ratio = 1.5
Distillate is liquid
Pressure = 130 kPs throughout
Cumene recovery = 99.9 percent in bottoms
Distillation unit 2: Number of theoretical stages 30
Reflux ratio = 1.5
Distillate is liquid
Pressure = 101.325 kPa throughout
Cumene recovery = 90 percent in bottom product
Recycle heater: outlet temperature = 120oC

Final Simulation Results:

Results Value

Total energy consumed

Total energy required
Temperature of the condenser
(second distillation column)
Temperature of the reboiler
(second distillation column)
Vapor fraction of the stream entering the
first distillation column

2
 Equipment Name in
Heuristic
Hysys
H9: Separate liquid mixtures using distillation, stripping,
enhanced (extractive, azeotropic, reactive) distillation, liquid-
liquid extraction, crystallization, and/or adsorption.

H10: Attempt to condense or partially condense vapor mixtures

with cooling water or a refrigerant. Then use Heuristic 9.

H11: Separate vapor mixtures using partial condensation,

cryogenic distillation, absorption, adsorption, membrane
separation and/or desublimation.

H26: Near-optimal minimum temperature approaches in heat

exchangers depend on the temperature level as follows:
5° C (10° F) or less for temperatures below ambient.
10° C (20° F) for temperatures at or above ambient up to 150° C
(300° F)
30° C (50° F) for high temperatures.
150° C (250° F) to 200° C (350° F) in a furnace for gas
temperature above inlet process fluid temperature.

H27: When using cooling water to cool or condense a process

stream, assume a water inlet temperature of 32°C (90°F), from
cooling tower, and a maximum water outlet temperature of 50°C
(120°F).

H31: Estimate heat-exchanger pressure drop as follows:

1.5 psi for boiling and condensing
3 psi for a gas
5 psi for low-viscosity liquid
7 – 9 psi for a high-viscosity liquid
20 psi for a process fluid passing through a furnace

H43: To increase the pressure of a stream, pump a liquid rather

than compress a gas, unless refrigeration is needed