UNIVERSITY OF KHARTOUM

FACULTY OF ENGINEERING
CHEMICAL DEPARTMENT

STYRENE MANUFACTURE
Salma Elgaili Abdel-Kareem Salma Mohammad Ali
Salma Hashim Elsadik
Shaimaa Al-Rasheed Mohammed

Supervised by:
Dr. Kamal Eldin El-Tayeb Yaseen
1
Safety,
 Economic
Process Introduction.
Description
Equipments'
Storage considerations.
and
Design, Balances.
considerations
Control
Ancillaries. and
and
HAZOP
Plant Layout.
Analysis.

OUTLINES

1 2 3 4 5 6

2
INTRODUCTION

3
 STYRENE MARKET*
* Reference: International Trader Publications, Tarrytown, NY 10591, U.S.A. 4
 STYRENE MARKET* 5
* Reference: International Trader Publications, Tarrytown, NY 10591, U.S.A.
 40697.67 kg/hr
Production Rate = 300 kT/yr

STYRENE MARKET 6
 PRODUCTION METHODS
1. Pyrolysis of petroleum recovery.

2. Oxidation of ethylbenzene.

3. Side-chain chlorination of ethylbenzene.

4. Alkylation of toluene.

5. Dehydrogenation of ethylbenzene.

6. Production of styrene from ethane and benzene.

7
Unit 100 Ex-101 R-103 V-101 R-102 T-101 C-101 R-101 E-101 P-101

Expander Trans-alkylation reactor Flash Alkylation reactor Distillation compressor Dehydrogenation reactor Heat exchanger Pump

PFD

8
 EQUIPMENTS’ DESIGN,
CONTROL AND HAZARDS

1) DEHYDROGENATION REACTOR

Designed by:
Salma Elgaili
9
 DEHYDROGENATION REACTOR
Ethylbenzene ↔ Styrene + H2

Ethane ↔ Ethylene + H2

Ethylbenzene → Benzene + Ethylene

Ethylbenzene + H2 → Toluene + Methane

Toluene + Methane → o-Xylene + H2

Ethylbenzene + Ethylene → 1,4-Diethylbenzene

* Reference: Wenner, R. R. and E. C. Dybdal, Catalytic Dehydrogenation of Ethylbenzene,

Chem. Eng. Progr.,44, 275 (1948). 10
 DEHYDROGENATION REACTOR
Dehydrogenation Reactor Specifications
Type Fluidized bed

Operating pressure 1.2 atm

Catalyst Regeneration
Operating temperature 6000C
Dehydrogenation

Material of construction Stainless steel

Reactor

Height 5.21 m

Shell internal diameter 10.8 m

Wall thickness 0.004 m

Volume of reactor 148.8 m3

Number of reactors
5
required
GHSV 846.6 hr-1

* Reference: US Patent 2002/0183573 A1 11

DEHYDROGENATION REACTOR
SENSITIVITY
REACTOR CONTROL
ANALYSIS

12
 EQUIPMENTS’ DESIGN,
CONTROL AND HAZARDS

2) ALKYLATION REACTOR

Designed by:
Salma Mohammad
13
 ALKYLATION REACTOR
𝐶6 𝐻6 + 𝐶2 𝐻4 ↔
Property 𝐶6 𝐻5 𝐶2 𝐻5
Value
Temperature 400oC
𝐶6 𝐻5 𝐶2 𝐻5 + 𝐶2 𝐻4 ↔ 𝐶2 𝐻5 𝐶6 𝐻4 𝐶2 𝐻5
Pressure 369 psig
Conversion 23.9%
Type of reactor Fixed bed reactor
Flow pattern Plug flow
Operation isothermal

∗
𝐤 𝟏 𝐏𝐁 𝐏𝐄 − 𝐤 −𝟏 𝐏𝐄𝐁
−𝐫𝐁 =
(𝟏 + 𝐊 𝐁 𝐏𝐁 + 𝐊 𝐄 𝐏𝐄 + 𝐊 𝐄𝐁 𝐏𝐄𝐁 )𝟐

Ei0
k i = k io exp (− )
RT
Ej0
K J = K j0 exp
RT

* Reference: Langmuir-Hinshelwood absorption-reaction model. 14

ALKYLATION REACTOR

14
 ALKYLATION REACTOR
HAZOP STUDY
Guide Word Cause Consequence Recommendation
-Regulatory monitoring and
-Affect the reaction.
-High flow Maintenance for controlling
-Affect the
High Pressure rate of system.
mechanical structure
gaseous feed. -Changing the damaged valve
of reactor.
system.
-Fault in
temperature
High -Increase vapor which will
controller -Produce undesirable
increase the pressure of the
Temperature -Low feed products.
column
-Fault in
steam valve

-Low amount -High undesirable

Reaction Too materials. -Check catalyst level and
of catalyst.
activity.
Slow -High flow -Decrease in the -Check inlet valve.
rate of feed product quality.
-Potential
-Low
injuries/fatalities if
temperature -Install low temperature/ high
Extra Phase people in area.
-High pressure control alarm.
-Transportation
pressure.
problems. 15
 EQUIPMENTS’ DESIGN,
CONTROL AND HAZARDS

3) GAS-LIQUID SEPARATOR

Designed by:
Shaimaa Al-Rasheed
16
 VERTICAL VAPOUR-LIQUID SEPARATOR
Head :
Dished
t = 0.0037 (m)

Wall :
di = 0.7716 (m)
t = 0.0005 (m)

Height :
2.47 (m)

Operating Conditions :
T = -155 (oC), P = 10 (psig)
17
VERTICAL VAPOUR-LIQUID SEPARATOR

18
VERTICAL VAPOUR-LIQUID SEPARATOR

HAZOP STUDY
 Regulatory

 High pressure monitoring and

 Low pressure Maintenance for

Recommendations
 High level controlling system

 Low level  Changing the

damage valve
system.

19
 EQUIPMENTS’ DESIGN,
CONTROL AND HAZARDS

4) STYRENE DISTILLATION COLUMN

Designed by:
Salma Hashim
20
 STYRENE DISTILLATION COLUMN
Type of condensation Partial
Type of trays Sieve tray
Actual reflux ratio 0.553
Actual No. of stage 21 stages
Column efficiency 62.65%
Column diameter 1.98 (m)
Plate spacing 0.6 (m)
Height of column 15.6 (m)
Wall thickness 7 (mm)
Down-comer Single path
Hole diameter 0.01(m)
No. of holes 3455 holes
Plate thickness 0.01(m)
Weir length 1.53(m)
Weir height 0.04(m) 22
 EQUIPMENT SIZING

•Transalkylation Reactor (Fixed Bed):

Weight of Catalyst = 143.91 kg
Reactor Volume = 0.457 m3

Column Column Column

Column
Length Diameter Thickness NO. of stages
NO.
(m) (m) (m)

T 101 8.25 3.38 0.005 5

T 102 37 4.5 0.059 31
T 103 10.56 1.86 0.005 15
T 104 30.7 4.5 0.007 30
T 106 19.2 0.6 0.011 35
T 107 8.2 0.29 0.006 22

22
 ANCILLARIES DESIGN

•Centrifugal Compressor
•Turbo-Expander
•Centrifugal Pump E 103
1. Power = 1145.7Power
(kW) = 175.9 (kW)
Power = 2201.39 Benzene
(kW) Storage TankType Shell and Tube
2.Item
Power = 19287.3 (kW)
Quantity
Parameter Area
Values 67m2
Storage tanks 1
U 380 w/m2.0K
Residence Time
Pumps 4 days
Number
1
of Tubes 219
Height
Compressors 28.5 Diameter
Tube Outside m2 20 mm
Diameter Tube14.25 m
Thickness 1.6 mm
Expanders 1
Volume 4543.78
Tube m3
length 4.88 m
Heat exchangers
Feed Hold-Up 22.8 m6
Bundle Diameter 0.43 m
Shell Diameter 0.5 m
Baffle Diameter 0.25 m

23
 SAFETY and STORAGE
CONSIDERATIONS AND PLANT LAYOUT
1. FormationCheck
of explosive
Point and combustible
Interval mixtures.
Remarks
2.Uncontrolled polymerization.
2-3 times weekly
Inhibitor Analysis
Daily If above 25-300C

2-3 times weekly

Polymer Analysis
Daily If above 25-300C

Colour 2-3 times weekly Easier in vapour phase

Oxygen Weekly

Monomer Temperature Daily

Monomer Vapour Temperature Daily

24
Plant Layout

25
COST ESTIMATION
Parameter Value

Total Capital Investment (T.C.I) 28,314,328.1 ($)

Total Product Cost (T.P.C) 8,316,393,555 ($)

Pay Back Period (PBP) 4 years

Net Present Value (NPV) 37,739,114.12 ($)

Internal Rate of Return (IRR) 48 %

Average Annual Revenues (AAR) 13,266,576.82 ($)/yr

26
THANK YOU

27