3158

FVO Nr.
Fabrieksvoorontwerp
Vakgroep Chemische Procestechnologie
Onderwerp
Selective Hydrogenation of Methylacetylene (MA) and
Propadiene (PD) present in the C3 Naphtha Cut.
Auteurs Telefoon
A.D. Hommerson 015-2840272
A. Meyer 015-2131472
E.J. Nijman 015-2617978
T. Xie 078-6187891
Keywords
methylacetylene, monolith, propadiene, propane,
propylene, selective hydrogenation
Datum opdracht 06-10-1995

Datum verslag 19-01-1996
.~'
T U Delft Faculteit der Scheikundige Technologie en der Materiaalkunde
Technische Universiteit Delft

FVO Nr.
Fabrieksvoorontwerp
Vakgroep Chemische Procestechnologie
Onderwerp
Selective Hydrogenation of Methylacetylene (MA) and
Propadiene (PD) present in the C3 Naphtha Cut.
Auteurs Telefoon
A.D. Hommerson 015-2840272
A. Meyer 015-2131472
E .J. Nijman 015-2617978
T. Xie 078-6187891
Keywords
methylacetylene, monolith, propadiene, propane,
propylene, selective hydrogenation
Datum opdracht 06-10-1995

Datum verslag 19-01-1996
Selective Hydrogenation of MAPD present in the CJ Naphtha Cut
Summary
In this report, the preliminary design of a process for the production of polymer grade
propylene by selective hydrogenation of methylacetylene (MA) and propadiene (PD) is
described. Currently, most MAPD hydrogenation processes are based on a triclde bed process.
In this design, a monolith reactor is used. Advantages of a monolith reactor are a very low
pressure drop, an even distribution of the reactants and thus less chance of hot spot formation
and a large catalyst surface area.
The plant, which operates 8000 hr/yr, has an annual production of 376 kton propylene of
99.6% purity. The product yield is 0.94 ton product/ton raw material and the propylene yield
is 1.02 ton propylene in product/ton propylene in raw material. The process consists mainly
of two steps:
1. Hydrogenation of MAPD
2. Separation of propylene and propane
The exothermic hydrogenation is carried out adiabatically in a monolith reactor, operating at

20 bar and 40 C. The heat of reaction is removed by cooling the reactor recycle stream. In
the reaction step, the MAPD content is reduced to 10 ppm. The propylene and propane are
separated by distillation at 19 bar.
The by-products in this process are either further processed or used as fuel gas. Therefore, it
is an environmental clean process.
The total estimated investments are 109.8 Mfl. For a project t~me of 15 years, the total costs
are 235 Mfl/yr. The profits are 11.6 Mfl/yr. For the eCOn0l
" ic rentability is found:
Pay Out Time (POT) = 2.8 years
Return On Investment (ROl) = 12.2 % .
lnternal Rate of Return (IRR) = 8.6% ~ 1 7
f~..(j .z.vl... ,
Table of contents
1 Introduction 1
2 Starting Points 2
3 Process Structure and Process Flowsheet 4

3.1 Motivation of the process structure 4
3.2 Thermodynamics 6
4 Process Flowsheet and Apparatus Calculations 7

4.1 Reactor 7
4.1.1 7
9
9
12
actor evaluation 12
13
4.2 Distillation~ 13
4.2.1 De ination of the number of trays
4.2.2 Eval . n of the column 15
4.2.3 Colu si zing 16
4.3 Flasher 19
4.4 Heat Exchanger 19
4.5 Pumps 20
5 Mass and Heat Balance 21
6 Apparatus Overview and Specifications 25
7 Process Control 29
7.1 Apparatus control 29
7.2 Time constants 29
7.3 Start up and shut down 30
8 Process Safety 31
9 Economics 32
9.1 Production cost 32
9.1. ro ction volume dependent costs 32
32
nvestments costs 33
9.2 Economic Criteria 35
36
9.2.1 ~ut Time (POT)
9.2.2 Re m on Investment (ROl) 36
9.2.3 em 1 Rate of Return (IRR) 36
ii
Selective Hydrogenation of MAPD present in the C J Naphtha Cut
10 Conclusions and Recommendations 37

10.1 Conclusions 37
10.2 Recommendations 37
Nomenclature 38
References 41
Appendices
I Description of the assignment 43
II Flowsheet and process strucrure 44
III Stream/component status 47
IV Specification forms of the apparatuses 51
V Apparatus ca1culations 58
VI Process safety 62
VII Economic ca1culations and tables 67
VIII Graphics data 72
1ll
Selective Hydrogenation of MAPD present in the Cj Naphtha Cut
1 Introduction
During the steam cracking of naphtha for the production of ethylene, useful byproducts are
fonned. One of these byproducts is propylene, which is concentrated as the top product of the
depropanizer. This top product is called the C3 cut. Besides propylene, it contains propane,
methylacetylene (MA) and propadiene (PD). To produce propylene of sufficient purity for
polymerization, the MAPD content has to be reduced to 10 ppm. This is usually done by
selective hydrogenation.
The aim of this project is to design an industrial plant for the production of polymer grade
propylene from the C 3 cut, with a capacity of 50 ton C3 per hour. Selective hydrogenation of
MAPD will be carried out in a gas-liquid monolith reactor and this design will be compared
dard MAPD hydrogenation method, the trickle bed process.
Currently two .quid phase MAPD hydrogenation processes exist [9, 17]:
1) Th yer process uses a multitube reactor in which the liquid trickles on the catalyst
in a hydrogen atmosphere. It operates isothermically at 15 C and 10-20 bar.
2) The IFP process uses a trickle bed reactor in which the heat of reaction is removed by
propylene evaporation.
3) ABB lummes Crest Inc., using a fixed bed reactor with the de-ethanizer bottom as a
feed.
The IFP process will be used for comparison of the monolith reactor and the trickle bed
process. /lol~" h .d,i ro~ ~E'~dj..? l
11 lJ~- rFP~~
Propylene is produced al most exclusively as a by-product of ethylene plants based on the
steam cracking of naphtha, gas oil or liquid petroleum. Production typically amounts to 40-
70% [14] of the total ethyl ene production. Propylene is also obtainerld by extraction from
refinery gas produced by catalytic cracking of oil fractions . In the Nefuerlands, propylene is
produced by Dow Benelux, DSM Kunststoffen and Shell Nederland Chemie.
Propylene is a colourless gas and is . ~oluble in alcohol and ether. It has a melting point
of -185.2C and a boiling p 'nt f -47.7 ~e.\ t is extremely inflammabie; its flash point is -
108e.
Polypropylene and sheet forms for packaging and as a filament for the
fabrication of ropes, fishin nets, etc. Injection moulded polypropylene is used in the
manufacture of automobile p rts, containers, household goods, etc [14].
Cr,,;..,;~ ""AAN- I' ..;"JJ ' t.- q4. t t-.r'~
1
PROPYLENE
LIGHT ENDS
...
U
"
-
PROPYLENE
H2 ..... GAS-LiQUID
SEPARATION
REACTION
-... DISTILLATION
J
1
PROPANE
1
CH,
Figure 1: Structure of the process

Selective Hydrogenation of MAPD present in the C3 Naphtha Cut
2 Starting Points
Polymer grade propylene has a purity of 99.6% and contains less than 10 ppm MAPD [51].
This means that MAPD and propane must be removed from the C3 cut. As is shown in
Figure 1, the designed process consists mainly of two steps. In the first step, the MAPD
content is reduced to 10 ppm by selective hydrogenation to propylene. In the second step, the
propylene and propane are separated by distillation. The MAPD could also be removed in this
distillation step, but this is dangerous because the MAPD mixture is explosive in high
concentrations (2-12 volume% in air) [6]. AIso, selective h~drogenation can improve the
propylene yield. ~ ~ ~~)
During the hydrogenation step, the following reactlOns take place: (7 .- lL..~{JL~
4 CH=C-CH3 + H 2 ---> CH2 =CH-CH3
A -r 1-12- ~ I~ r~U-
":"7
NiJ'Y'/
CH2=C=CH2 + H 2 ---> CH2 =CH -CH3 ~-+ 4 l ..-, lS ~,(Q ~~

I C~1::!-=-CH3 + H2 ---> CH3 -CH2 -CH3 f~c;.IV f-+ H2 ~~ 11 , I
~ H2 ---> C6H lO
The hYdrogen~l'Will be carried out in a monolith reactor. Advantages of such a reactor

above the standard trickle bed process are a very low pressure drop, an even distribution of
the reactants and thus Ie ss chance of hot spot formation and a l)Igy ca~J'yst surface area.
ij Mv~ ~ '>w?
To be able to make a good comparison between the monolith process and the trickle bed
process, the following parameters have been chosen to be the same as in the IFP process [9]:
- feed composition : see Table 1
- reactor product composition : see Table 1
- catalyst : Procatalyse LD 273, based on palladium
- operating temperature : 37-45 0 C
- operating pressure : 20 bar
Table 1: Composition of the IFP process streams before and after the reaction section.
Component Reactor feed Reactor product
composition composition
(wt%) (wt%)
Propylene 92.0 94.4
Propane 4.0 5.5
Methylacetylene 2.2 1 ppm
Propadiene 1.8 10 ppm
C 6+ 0 0.3
Bec.use only D is a11~ t e reacto r product, it is assumed that the reactor

effluent contai s 1 ppm MA and 9 ppm PD W~~~
The plant is locateu 0.< DS~Y~ ~u -ve een. The feed streams are taken from the existing steam
2
cracking plant. The C3 cut is taken from the depropanizer at 40 C and 22 bar [29]. Hydrogen
leaves the demethanizer at 109 K and 33.7 bar [25], and is assumed to be delivered at these
conditions. The hydrogen contains 10 mole-% methane. Except during the summer, river water
is available at 15 C and can be emitted at 40 C. When the riv er water becomes warmer than
15 C, chilled water is provided for by a chilled water installation which delivers water at 5 C.
Low pressure steam is available at 3 bar. The produced polymer grade propylene can be
delivered at the conditions at which it leaves the distillation column. The bottom product of
the column, the propane stream, is sent back to the steam cracker at 2 bar and 360 1<. [43].
Product gas streams which will be destined as fuel gas are delivered at 6 bar and room
temperature.
The compounds present in this process and some of their properties can be found in Table 2.
Table 2: Properties of the compounds that are present in the process [7, 33].
Component Structure Mw Tb P liquid 11 Ji~uid
(g/mole) CC) (kg/I) (10 Ns/m 2)
Hydrogen H2 2.02 -252.8 0.071 (-253C) 1.3
Methane2 CH4 16.04 -162.0 0.425 (-161 C) 2.0

Propylene C=C-C 42.08 I( b.4) 0.612 (-50 C) 8.0
Propane C-C-C 44.10 -42.1 0.582 (-42 C) 9.0
Propadiene C=C=C 40.06 -34.5 0.658 (-35 C) 12.6
Methylacetylene C=C-C 40.06 -23.2 0.706 (-50 C) 12.5

1,3-Hexadiene C=C-C=C-C-C 82.15 73.2 0.692 (20 C) 24
Water H 20 18.02 100 0.998 (20 C) 100
3
3 Process Structure and Process Flowsheet

3.1 Motivation of the process structure
This description of the process structure is based on the process flowsheet in Appendix Il.
As mentioned in the starting points, the delivered. C3 naphtha cracking cut is the top product
of the depropanizer and has a temperature of 40 C and a pressure of 22 bar. Vnder these
conditions, the C 3 hydrocarbons are in the liquid phase. The monolithic reactor (R4) is
operated at 20 bar and 37 C, exactl the same conditions as those used in the IFP process.
The reactor length is ca1culated .n e fact that in one pass the temperature of the reactor
feed stream may only increas 8 C e width of the reactor is ca1culated based on the
volume flow entering the reactor. 1
Because the hydrogenation reactions ar exothermic and a temperature increase of only 8
degrees in one pass is allowed (to av~igomerisation and polymerisation reactions and to
avoid catalyst deactivation), a recycle
structure is set up. The reaction heat of the
recycle stream is removed by heat exchange
Liq. in with cooling water and the temperature is
l H2 turned back to 3r C. The recycle stream
I dilutes the feed stream. During the practical
operation, the recycle stream will be pumped
up from the ground by pump P6 up to the
entranee of the monolith reactor which
covers a height of about 6 m.
No external H 2 recycle is needed because the

monolith reactor can be operated with
internal recirculation of the gas. That is
possible because the frictional pressure is in
balance with the hydrostatic pressure of the
liquid inside the channels. The different
monolith blocks are so flxed that there is
still an open space between two blocks
which allows the H2 gas to circulate through
the reactor (Figure 2). Some H2 will dissolve
into the liquid, and can be removed later at
the of the distillation col~It~.oy?
nsidered to remove the dissolved hydrogen
d methane with aflasher from the liquid
ow which leaves the reactor, but then too
uch propylene would also be removed as a
as. ere ore lt IS chosen not to remove the
hydrogen and methane until the distiljation /~
Figure 2: Internal recycle of H2 in a monolith step. I~' ~1
iJ
~ ~ .~L.1;lfo JU ~ ~
reactor [13].
4.L iJ ~~. wt"A ".J"" ~
4
Demethanizer feed sy em implemented by naphtha cracking is used to provide the hydrogen

stream. As mention earlier, the contents of the hydrogen stream used in this design are
specified by DS at is 10 mole- % methane and 90 mole- % hydrogen, under conditions of
109 K and 33.7 oar. The h dro en elivere as a 1 UI , IS flashed at constant pressure to
reduce e methane content. That is to avoid accumulation of methane in the reactor and to
make sure that not all methane has to be removed at the top of the distillation column which
is a difficult case. Qnly the small part of the methane that is not removed by the flasher will
leave the pro ce ss later at the top of the distillation column. The hydrogen temperatur~ e.s --1 \
increased to that of the reactor (3r C) using part of the reactor recyde stream. j .JI..
Wl-V~ ci.'f ~ /.J }
For the removal of methane from the hydrogen, a membrane gas separator was al 0
considered. It was found to produce a purer hydrogen stream, but also to be too expensive
because of the large recompression needed. Also was considered that it could be cheaper to
make use of the fact that the stream is delivered as a liquid.
To produce a product stream of polymer grade propylene, the propylene is separated from the
propane and the oligomers by a distillation column. The column is designed to produce
propylene of 99.6% purity. The column feed stream is on conditions of saturated liquid and
enters the column on half its height, that is about 50 m. The pump (P7) used to deliver the
column feed is designed on this height difference. This height was chosen based on values of
relative volatilities which vary along the length of the column. The column operates at a
pressure of 19 bar to make sure that the water used to condense the top stream will not
become higher than 40 C. To avoid light ends (hydrogen and some methane) in the product
stream, they are removed as the top product, two stages above the propylene product stream.
These light ends can be used as fuel gas, so a partial condenser can be used. To achieve a
propylene purity of 99.6 %, it is necessary to condense (partial) at 23 C. Except during some
time in the winter, cooling to and condensing at 23C is done by using chilled water of 5 C
as the cooling medium. Reboiling of the bottom stream can be achieved using low pressure
steam.
The choices of a actual reflux ratio of 11 and the practical number of trays in the column of
150 are based on shortcut calculations using Underwood's equation. These calculations are
described in detail in chapter 4. The reflux pump (Pll) used is designed to cover a height of
about 100 m (the column height).
It also was considered to make use of the so called heat pump in the distillation step [16] . In
this concept the column pressure will be lower than normal (e.g. 9 bar) and instead of using
expensive refrigerants for condensing the reflux stream, a heat pump will be used. This is
especially attractive for systems separating close boiling components such as propane-
propylene. The increase in relative volatility by decreasing the column pressure reduces the
capital expenditures significantly. This way, the savings in utility costs may offset the cost of
a compressor. A compressor is used to incorporate the heat pump concept. Column top
vapours are compressed to the saturation temperature which is about 15 C higher than the
bottom temperature. Since compression of the vapours results in superheating, the condensing
duty is greater than the reboiler duty, so the top stream can be used to reboil the bottom
stream without help of steam.
In this case, such a system can not be applied, because the top stream with the composition
which is the case in this design, can never be used to reboil the bottom stream. That is
5
because the temperature of the top stream with a heat duty great enough to reboil the bottom
stream is lower than the column bottom temperature which makes reboiling not possible.
Several heaters and valves are used to bring the outgoing streams, which will be used in
further processing or as fuel, on the right conditions. It was considered to make use of
expanders (instead of valves) to reduce the pressure, but that seemed to be not the right
economical choice.
3.2 Thermodynamics
For determining the heat of reaction, the following reactions are considered:
MA (1) + H 2 (g) propylene (1)

-+ (reaction 1)
PD (1) + H 2 (g)propylene (1)
-+ (reaction 2)
propylene{17~ ~ propaneA )
-+ (reaction 3)
2 ~H4 (1) C 6+ @
-+ I)! (reaction 4)
.}11'L . .
tnt-reaGt:H'**HrI~
exothermic so the reaction balance lies on the right side.
With the thermodynamic values mentioned in Table 7, the heat of reaction at 3rC can be
calculated (Appendix II).
reaction (1): ilHr310 = -164 kJ/mole

reaction (2): ilHr310 = -169 kJ/mole () t')
reaction (3): ilHr310 = -125 kJ/mole .r {
reaction (4): ilHr:31O =~-----=v
The enthalpy of the process streams is calculated by ChemCAD, using the Peng Robinson
model. For the process streams and the column calculations, the Peng Robinson equation is
used because this model gives the most reliable values for the relative volatilities of propane
and propylene. Because ChemCAD takes liquid at 298 K as the standard state for enthalpy
calculations, the enthalpy of formation is added and the heats of vaporization at 298 K is
subtracted.
In the flasher, the liquefied hydrogen and methane are separated by increasing the temperature.
The thermodynamic model used for the calculations is UNIFAC, because this model gives the
most reliable K-values.
6
4 Process Flowsheet and Apparatus Calculations

All calculations and obtained values are listed in Appendix V.
4.1 Reactor
4.1.1 Introduction
Monolithic reactors have unitary structures which contain many small, parallel passages
(Figure 3). Catalytic species are incorporated either into a thin layer of a porous oxide
deposited on the channel wall (so called washcoat) or into the wall itself (incorporated). The
monolithic reactor (MR) is widely used for gas-phase processes, predominantly in
environmental applications including automotive exhaust gas cleaning. It can also be used for
multiphase reactions. Most of the work on multiphase reactions has been devoted to liquid
phase hydrogenations. Until now, use of trickle bed reactors (TBR) for three phase
hydrogenations has been common practice .
. ..... " .
... :; ;.iii ~
................
.................
r:f(i; .
....................
~
,.
\
;
,
:
..................
::::::::::::::::::~~I
'
' 'l
'
...
....
. .
p.. ~I
[l.
Figure 3: Monolithic
support [13].
The difference between a TBR and a MR originates from the catalyst geometry which affects
the catalyst load, internal and extemal mass transfer resistance, contact area as well as pressure
drop. The main differences are summarized in Table 3.
7
Table 3: Differences between TBR and MR [13].

Aspect Trickle Bed Reactor Monolithic reactor
Catalyst weIl established techniques established for gas phase, at
manufacture developmental stage for liquid
phase
cost low high

Slze pellets, 1-5 mm channels, 1-4 mm
volumetrie catalyst 0.55-0.6 for conventional 0.05-0.25

load packings
<0.3 for shell catalysts
extemal surface area 1000-3000 m 2/m 3 1500-2500 m 2/m 3
pressure drop high for small particles very low
mode of operation pseudo steady state inherently unsteady
superficial velocities liq: 0.005-0.05 mis liq: 0.03-0.15 mis

gas: 0.05-1.5 mis gas: 0.05-1.00 mis
diffusion leng th 0.1(shell)-2.5 mm 50-150 \lm
Advantages of a MR compared to a TBR

- In a TBR, there is a substantial increase in the pressure drop as the catalyst particle
size is reduced. The frictional pressure is lower in a MR for all sizes of catalyst
particles, up to two orders of magnitude. For a MR operating in down-flow mode it
is possible to balance the frictional pressure with the hydrostatic pressure of the liquid
inside the channels. This essential zero net pressure drop makes it possible to operate
at constant pressure and will reduce the operating costs.
In processes involving fast reaetions, the MR will outperform the TBR, because it has
a higher throughput. Also, the diffusion length in a particulate catalyst particle is
longer than that in a MR and therefore fast reactions may become diffusion limited in
a TBR, which will decrease the selectivity.
Due to the structure of the monolith, the reactants move with the same velocity
through the whole reactor. Therefore hot spots, which often are formed in the TBR,
are not expected.
Disadvantages of a MR compared to a TBR

- A MR consists of many long parallel channels with a very fine and regular structure.
Therefore, it is expensive to manufacture.
- Especially for three-phase reaetions, operation of the MR is still in the developmental
stage.
8
4.1.2 Starting points for the reactor design
As mentioned in the Starting Points, conversion and catalyst are taken the same as those of
the IFP trickle bed process. The catalyst particles are incorporated into a washcoat instead of
into the monolith wall itself, because this way a higher catalyst surface area can be achieved.
The thickness of the washcoat is 30~m and the wall thickness is 150llm. The density of the
channels is 400 cells per sq. inch (cpsi) [13]. The catalyst can be cleaned insitu by stripping
with hot hydrogen which greatly lengthens the. intervals between regeneration. Without
cleaning, regeneration by burning of coke needs to be done aft er four years [10].
The following reactions take place:

(1) CH=C-CH3 + H2 ---> CH2 =CH -CH3
(2) CH2 =C=CH2 + H 2 ---> CH2 =CH -CH3
(3) CH2 =CH-CH3 + H 2 ---> CH3-CH2 -CH3
(4) 2 C3H 4 + H2 ---> C6H lO
All reactions are exothermic.
The reaction rate of the hydrogenation of MA is given by [13, 34]:

E
rMA = E catP calexp [-
(1)
in which:
r MA = reaction rate of MA [mole/m3reactojs]
Ecat = porosity of the catalyst [m3catalyjm3reactor]
P cat = density catalyst [kg/m3] - -,
r: ko
R
a
= specific reaction rate [m3reactojkg/s]
= actlv . 1!!Q..eL
= gas constant [J/mole/K]
--
T = temperature [K]
~A = concentration of MA [mole/m ]
3
3
C H2 bulk = concentration of hydrogen in the liquid bulk [mole/m ]
With the subscript reactor the empty channels of the monolith block are meant.
I I
According to Derrien [9] an approximation of the reactivity ratio of MA to PD and of PD to

propylene is 1.8 and 400 respectively.
Given the feed and product compositions, the total heat of reaction can be determined exactly.
The temperature rise caused by this heat of reaction is more than allowed, because then all
reactants will vaporize. If a maximum temperature rise per pass through the reactor is known,
the conversion which takes place during one pass can be determined. This conversion can be
achieved by diluting the feed stream by means of a recycle loop. The length of the monolith
can be calculated from this conversion. Qnly the conversion of MA is considered. The width
can be calculated from the volume of the flow entering the reactor
9
4.1.3 Model
For describing the flow pattem, Taylor flow can be assumed [13] . That
means that the mixture of reactant gas and liquid moves through the G,L G,L
channel as a sequence of plugs (Figure 4). i- i-
, ' , ~ ~ I, ~
To describe the Taylor flow, a very detailed model is necessary. To

simplify this model, it is assumed that no liquid .plugs exist, but that a
liquid film along the wall with gas in middle of the channel is moving
downwards. The hydrogen diffuses from the gas phase through the liquid
o
'~j: ~.
., .. :
film to the wall. This is areasonabie assumption, because according to ~~, .
Edvinsson [13], in the Taylor model almost 97% of the hydrogen diffuses
via the prismal part of the gas plug and only 3 % via the spherical ends. " t
~. ! ': "
Model assumptions:
gas and liquid phases are uniformly distributed over the reactor
cross section
o
: .~.
': . .
.
adiabatic operation
.~~~;~~~
cocurrent down-flow
steady state operation
no mass-transfer resistance on the gas-phase side
all physical parameters are treated as constants Figure 4: Taylor
consecutive hydrogenation reactions flow [13].
the reaction takes place at the catalyst surface
methane is not considered as a reactant
formation of C6 + is not considered
The mass transfer balances are given by the following equations [13] :
Hydrogen transfer from gas to the liquid film :

dCH2 kasa (2)
- - = --(cn. bulF eHJ
dz u 2- 2
in which
CH2 = concentration of H 2 in the gas phase [mole/m3]
z = monolith length parameter [m]
kos = mass transfer coefficient fm/sJ
a = specifc area of gas phase [m2/m 3]
u = superficial fluid velocity fm/sJ
cH2 * = concentration of H2 on the gas-liquid interface [mole/m3]
been used.
10
Selective Hydrogenation of MAPD present in the C j Naphtha Cut
The value of C H2 * can be found by:
(3)
in which:
YH2 mole fraction H2 in the gas phase [-]
=
H Henry coefficient of hydrogen in propylene [bar.m3/mole]
=
= reactor pressure [bar]
No Henry coefficient of hydrogen in propylene could be found, so a valuej
-
15000 bar.m3/mole is chosen.
Hydrogen transfer through the liquid film:

dC~.buJk (4)
dz
in which:
v H2 = total reaction stoichiometric coefficient of hydrogen [-] = -(1 + 1/1.8 + 1/1.8/400)
Mass balance over MA:
(5)
in which:
v MA = stoichiometric coefficient of MA [-] = 1
Energy balance:
dT rMA Cv MA!:::.~U4 + VPD !:::.~PD+ v PP !:::.~pp)

(6)
dz Cp L U PL,mole
in which:
!:::.Hr.MA = reaction enthalpy of the hydrogenation of MA [kJ/mole]
!:::.Hr,PD = reaction enthalpy of the hydrogenation of PD [kJ/mole]
!:::'Hr.pp = reaction enthalpy of the hydrogenation of propylene [kJ/mole]
v pD = stoichiometric coefficient of PD [-] = -1/1.8
v PP = stoichiometric coefficient of propylene [-] = -1/1.8/400
Cp,L = overall heat capacity of the liquid [J/mole/K]
PL,mole = mole density of the liquid [mole/m3]
11
4.1.4 Results and discussion
From the differential equations 2,4,5 and 6, CMA an T are calculated, with aid of RRStiff, after
a block of monolith of 30 cm. The concentrations of hydrogen and MA in the channel
decrease, but before the liquid flow enters the next block of monolith, the hydrogen
concentration will return to its starting value due to the intemal recirculation in the free space
between the two bloeks of monolith. Such operation process is repeated after every 30 cm.
The channellength, which is necessary for the expected convers ion is calculated to be 5,13 m.
With a free space of 0.05 m between two blocks, the total length of the monolith becomes
6 m. The decrease of the MA concentration and the increase of the temperature in one
monolith block are shown in Figure 5. (Data in Appendix VIII).
cma (mole/m3) T(K)

24.7 310.04
erna
24.68 ~
310.03
24.66
24.64 310.02
24.62
310.01
~T
24.61
24.58 310
0 0.05 0.1 0.15 0.2 0.25 0.3
z(m)
Figure 5: Decrease of the MA concentration and

increase of the temperature in a monolith block.
4.1.5 Reactor evaluation
Due to the assumptions that have been made, the following critical notes can be drawn:
The calculated length of the reactor is based on the conversion of MA only. Tt is
hereby assumed that the conversion of the other components will also match the
eonversion in the IFP process, although this is probably not the case.
In the model used, the hydrogen concentration in the liquid bulk and thus the reaction
rate of MA is not dependent on the decreasing hydrogen concentration in the gas
phase. This makes it difficult to control the conversion by means of the hydrogen
pressure.
The following parameters used in the model are not exactly known and have been
estimated: ratio of reaction rates, the Henry coefficient H, the superficial fluid velo city
u, and the mass transfer coefficient kas.
12
4.2 Distillation
4.2.1 Determination of the number of trays
The column is designed to produce propylene of 99.6% purity and to have a propylene
recovery of >90%. To achieve this recovery, the bottom product is chosen to contain 90%
propane and about 10% propylene. The following design procedure is followed [28]:
Based on a feed containing propylene and propane only:

specifying the separation
setting the column pressure
determining the minimum reflux
selecting several ratios of actual reflux to minimum reflux. For each, determining the
theoretical number of stages with a shortcut calculation. Determining the optimum
(most economic) reflux ratio.
Based on the actual column feed:

performing rigorous calculations with the ChemCAD flowsheet simulator
The column pressure and the condenser type have been deterrnined by the algorithm described
in [44]. The minimum distillate temperature has been fixed to be 45C so as a coolant water
can still be used. Doing so, a column pressure of 20 bar and the use of a partial condenser is
deterrnined.
Shortcut calculations to roughly determine the minimum reflux ratio and the number of trays
for different reflux ratios are performed. The minimum reflux ratio is calculated with the
Underwood equation [44]:
ZD (l-zJ
(-)-a--
zp (l-z) (7)
~n= (a-I)
in which:
~in = minimum reflux ratio = LfD [-]
L = reflux flow rate [molels]
D = distillate flow rate [molels]
ZD = mole fraction propylene in distillate [-]
ZF = mole fraction propylene in feed [-]
ex = relative volatility [-]
a= y(l-x) (8)
x(l- y)
in which:
y = mole fraction propylene in vapour phase [-]
x = mole fraction propylene in liquid phase [-]
Equation (7) is only applicable if the feed is at saturated liquid conditions. With this equation
a minimum reflux ratio of 11 is calculated. The actual reflux ratio R depends on economic
13
factors. The costs of the distillation column are made up of capita I costs and operating costs.
The capital costs are largely determined by the number and diameter of the trays and the
operating costs by the steam and cooling water requirements. Practical values of RjRmin lie
between 1.1 and 1.5 [44]. Por several values of RlRmin' a shortcut calculation of the number
of theoretical trays is performed using the Smoker equations [44] . This method is developed
for systems with very low relative volatilities, which is the case for propane and propylene.
The Smoker equations split the column in a rectifying section (top section) and a stripping
section (hottom section), each using its own relative volatility.
x~(1-{3x)
ln(. . )
x n (l-{3.xo) (9)
~ors=
ln(~)
mc 2
in which:
~ = mc(a-1)/(a-mc2)
c = 1+k(a-1)
and
m(a-1)k2 + (m+b(a-1)-a)k+ b = 0 (10)
Por the top section:

Nr = number of theoretical trays in the top section [-]
x'o = Xo - k
x'n = ZF - k
m = R/(R+1)
b = xo/(R+1)
Por the bottom section:

Ns = number of theoretical trays in bottom section [-]
x'o = ZF - k
x'n = XB - k
(11)
XB(ZF-X~
b= (12)
(R+ 1) (ZF- x~
Xo = mole fraction propylene in liquid phase in distillate [-]

XB = mole fraction propylene in vapour phase in bottom stream [-]
Por the calculation of the actual number of trays, the theoretical number of trays has to be
divided by the efficiency of the column. This is chosen to be 0.9 [16]. Por several values of
RtRmin between 1.1 and 2.0, the actual number of trays are calculated. A good approximation
14
of the optimum RlRmin can be found by plotting N(R+ 1) against RfRmin' The optimum
operating reflux lies where N(R+1) has its minimum. The following results are found:
N(R+l)
4000 r - - - - - - - - - - - - - - - - - - - - - ,
3600
3200
2800
2400 ' - - - - - - - - - - - - - - - - - - - - - '

1.2 1.4 1.6 1.8 2
RIRmin
Figure 6: Determination of the optimum reflux .
With the reflux ratio and number of trays obtained using the foregoing method, a rigorous
calculation is performed using ChemCAD. The calculations are based on the actual feed. To
remove the light ends (hydrogen and methane), two trays are added on top of the column and
the propylene product is thus removed as a si de stream.
The partial condenser operates at a lower temperature than the column, because at higher
temperatures too much propylene would be removed with the light ends. The reflux stream
is decreased to give the highest possible condensation temperature while still meeting the
propylene purity requirements.
4.2.2 Evaluation of the column
The following critical notes can be drawn about the distillation column:
The shortcut calculations are based on a feed containing propylene and propane only.
This means that column pressure, reflux ratio, number of trays and optimum reflux
ratio are determined for this feed, using a distillate temperature at which cooling water
can still be used (45C). With the optimum reflux ratio and corresponding nu mb er of
trays, rigorous calculations, using the actual column feed, are performed. With these
calculations however, a condensation temperature of 23C (at which normal cooling
water can no longer be used) is found.
The separation of propylene and propane is very difficult to design. The relative
volatility of the two components is not only close to 1, it also changes with pressure
and composition. For the short cut calculations, only two different values for the
relative volatility are used, 1.1 for the bottom section and 1.08 for the top section.
15
4.2.3 Column sizing
Column diameter
The colunm diameter is calculated using the following relations [44]:
deol = (
4Mo 05
) . (13)
Ppr p OUO;nax
UO,max = (14)
in which:
dcol = column diameter [m]
MG = gas mass flow rate [kg/sJ
3
PG = gas phase density [kg/m ]
3
PL = liquid phase density [kg/m ]
uG, max = maximum allowable superficial gas velo city [mfs]
Pr = ratio of operating gas velo city to maximum allowable superficial gas velocity [-]
C tr = capacity coefficient [mts]
The capacity coefficient is obtained fIOm:
Cu = 0.0129+0.1674 T.s+ FLdO.0063-0.2682 T)+Frd -0.008+0.1448 T) (15)
in which FLG is the liquid-vapour flow parameter:
F LO ML( Po)o.s (16)

=
Ma PL
and
Ts = tray spacing, distance between two adjacent trays [m]
ML = liquid mass flow rate [kg/sJ
16
The capacity coefficient is corrected for the surface tension:
c' == C (~)O.2 (17)

tr tr 0.02
in which:
C t/ = corrected capacity coefficient [mIs]
a = surface tension [NIm]
Column height
The column height can be estimated from [44]:
(18)
(19)
in which:
heel = total column height [m]
hTB = height between top and bottom tray [m]
Ncel = number of actual trays == N/Ecel [-]
N = number of theoretical trays [-]
Ecel = overall column efficiency [-]
Here it is assumed that the height above the top tray is 1.5 m, the height below the bottom
tray 2.5 mand the skirt 2 m [44] .
Tray design
The active tray area is estimated as:
Aa == Acor 2A d (20)
in which:
2
Aa = active tray area [m ]
2
Acel = total column cross section area [m ]
2
Ad = area occupied by downcomer [m ]
The weir length (Lw) is chosen to be 70% of the column diameter. The downcomer diameter
and the downcomer area are then found from Coulson [7].
17
The total hole area as a fraction of the active tray area is given by:
(21)
in which:
2
Ah = total hole area [m ]
dh = hole diameter [mm]
lp = hole pitch (distance between the hole centres) [rnm]
The number of holes per plate (Nh) can then be found by:
4Ah
M =-- (22)
h d2
7T h
18
4.3 Flasher
Gas-liquid separator VI is designed to separate as much hydrogen as possible from the

incoming hydrogenjmethane stream. The hydrogen willieave the separator as a gas at the top
and the methane as a liquid at the bottom. The separation is done by increasing the
temperature from 109 K to 124 K at constant pressure. The flasher is designed to have a
hydrogen recovery of 90 mole-%. Flash calculations were done using ChemCAD.
In this separation step 53 mole- % of the total methane content can be removed. The -rest of
the methane will be removed at the top of the distillation column later in the process.
To size the separator the following equation is used [7]:
, = 0.035 ~ PL (23)
Pv
in which:
v = maximum design vapour velocity [mis]
PL = liquid density [kg/m 3 ]
Pv = vapour density [kg/m 3]
Knowing the vapour volumetrie flow rate and both densities, the diameter of the vessel can
be calculated. Above the liquid level, a disengagement height equal to the vessel diameter
should be provided for [7]. The liquid level depends on the hold-up time. A typical value for
the hold-up time is 10 minutes [7].
The performance and size of top-accumulator V13 are calculated the same way.
4.4 Heat Exchanger
The function of heat exchanger H3 is to heat the H 2 gas stream leaving flasher from -149 C
to 3r c. This stream is heated by a part of the reactor recycle stream. 1t is chosen to take 10
volume% of this recycle stream to make both streams in the exchanger of ab out the same size.
Because of the extensive cold of the gas stream, it is expected that the propylene stream will
be frozen immediately if it would enter the heatexchanger in the tubes. Therefore the
propylene stream is put in the shell side and the H 2 stream in the tube side of the exchanger.
r
The overall heat-transfer coefficient is 100 W/m 2 C [7]. It accounts for the ice layer on the
tubes which will decrease the overall heat transfer coefficient. The low temperature can cause
brittle failure in the metal used in the exchanger. Austentic stainless steel is chosen as material
for the tubes because of its resistance against low temperatures. The number of tube passages
is chosen to be 2 and the number of shell passages to be 1. This way the correction factor for
the logarithmic mean temperature difference is 0.97 which is close to 1. The capacity, the
heat-transfer area and the temperature drop of the propylene stream are calculated with aid of
ChemCAD.
19
4.5 Pumps
To transport the liquid to the next apparatus, pumps are used. The height over which the liquid
has to be transported and the volume of the flow determine the type of pump. Por all pumps,
the centrifugal pump is chosen [7], because its maximum capacity is larger than the largest
stream in this process, the recycle to the distillation column (1600 m3fh). The height
determines the pressure difference.
According to Coulson & Richardson [7], the efficiency of a pump is dependent on its capacity.
Por all pumps an efficiency of 0.85 is chosen. The theoretical and practical power of the
pumps have been calculated with aid of ChemCAD.
20
5 Mass and Heat Balance
21
IN Forward Mass and heatbalance Back OUT

M M
M Q M Q
Q Q
0.261 -1670.1 I ei) ~?

MI
0.073
-827.7
--. -. r -
-. -- .~
0.188
---{1
-8942.1
0.073 VALVE
938.8
----
0.022 -633.0
~ 1---'
"':1 CorrlFrmk> 0.022 -638.0
~1 <S\ h.,1~
.I 0.073 988.6
(1l ~ 49.11
~-- ---
-2200.0
4
442.0
H3 ~---
-11410
0.188 ~ 49.11
-~ ~- - --
-8010.6 .r-- -1267.7
50.00 19338 I !:roo~IJ'.N',

,
"t@ - - 491.1
I
VALVE -12677
50.00
- _. ---- ---~
19354
-~
541.1
-- - -- -- ~
r---
491.1
-6909.3
R4 J.
-26319
541.2 491.1
-
-14920 -.---@t ....~ - -12677
r----L-- Ir 491.1
r
LOOI - "",Jnl"
158.6 -8946.1 - 158.6 3tb'~:r
IJ -. - -13609
\-Is
50.19 ,
.~
-1295.7 I-[!i)
' 1
Mass in tonfh
Heat in MJ/h
22
IN Forward Mass and heatbalanee Back OUT

M M
M Q M Q
Q Q
541.2 49L1
--@
-14920 ~ -12677
, "J) ~
491.1
v" " ,
-12677
Pb
50.19
-.@:
-1295.7
i-
Pt
50.19
-1287.7
--------ii
...... l'
631.7 631.4
-@ @-
4.685 .10'
18 -1.768.10'
~
634.4
--- - ~ I--' 47.02 13559
-4.25. 10 6 - - --"@
- - - -..:
t-+-
2.93
-- - . _. - .- - -
631.4
-14173 I 6
!
!
Qi
-4.23. 10
I VALV~
@ - - --
631.4
~ .- -3.97. 10
2.93 I
~
4920.0 ~ ~
I I 1.0 -3.22. 106 lli.lf!a,

-1---1
~~ t - - _I~ 111.0 -3.47. 106
~r=
, GiJ

@ I'
I~
H,o ~
Irbllp,j
1993.0 -6.33. 10' 1993.0 -6~ 32 . 10'
(iJ
~
631.7
-- -- . ---~-
1.765. 10'
Mass in tonfh
Heat in MJfh 23

r---------------------------,
r-------------------------~----------------,
, : '
CHILLED WA TER', :
,
J
',
'
FUEL GAS
PROPYLENE
,
COOLING WA TER :
, 81 6.8 ,
, ________________________ .J'
~
PROPYLENE
O.U ltJ' 01 ,
,,
L __________ ..J
LP STEAM
LP STEAM
,
__ .J
FUEL GAS
TO STEAM CRACKER
LP STEAM
FLOWSHEET FOR THE SELECTIVE HYDROGENATION OF MAPD

V 1 GAS-LiQUID SEPARATOR
H 2 HEATER IN THE C3 NAPHTA CRACKING CUT WITH A MONOLITH REACTOR
H 3 HEA TEXCHANGER
R 4 MONOLITHIC REACTOR
H 5 COOLER A.D. Hommerson
P 6 PUMP A. Meyer
P 7 PUMP
T 8 PP SPUTIER E.J. Nijman
H 9 REBOILER T. Xie
H 10 CONDENSOR
P 11 PUMP FVO No. 3158
H
V
12
13
HEATER
TOP ACCUMULATOR
STREAM NUMBER 12731 TEMPERATURE K 0 PRESSURE BAR A
IN Forward Mass and heatbalanee Back OUT

M M
M Q M Q
Q Q
631.7 631.4
h
1.765. 10 5
.ij;
, ~ ~
- 1.768. lO'
2.93 631.4
- - --@ - -
4920.0 Pit ~ 1.769. lO'
~
A
+
_-t
0.063 -1840.0 LPd!t\n , (O",J~rf' ,
t-- -. 0.063 -1980.0
Hl'!.
~ I(PArIl'E R 2.93 5064.4
'(@ ~
~ ,
0.239 V3I
,
,
-275.1 ,
)
-, .. ~ I
YAlVE l11) furl ertS 0.239 1143.2

J
2312.9 -6.65. 10' <= Total = 2312.9 -6 .6610 "1
Mass in tonfh FVO No. 3158

Heat in MJfh
24
6 Apparatus Overview and Specifications

(Specification fonns can be found in Appendix IV)
Almaratus S:gecification List for reactors , columns and vessels

Apparatus No. VI R4 T8 V13
Name gas/liquid reactor column top

separator accumulator
Type vertical vessel monolithic distillation horizontal
Pressure [bar]
abs./eff. 33 .7 20.0 20 19
Temp. [0C] -149.0 40 45 23.0
Volume [m3] 0.033 16.8 1552 269

Diameter [m] 0.40 2.07 4.31 8.0
Lor H [m] 0.95 5.0 106 5.35
Packing:
Trays (number) 166 (actual)

Fixed packing
Catalyst type Pd (LD-273)
Catalyst shape 13 vol-% Pd
impregnated in
the monolith
Monolithic bloek:
-volume [m3 ] 2.44
-diameter [m] 1.97
-Iength [m] 0.80
Special material
Number
- serial
- parallel
Other 5V4 monolith product from

blocks in the side stream
reactor
25
Apparatus Specification List for heat exchangers and furnaces

Apparatus No. H2 H3 H5 H9 HlO
Name heater heater cooler reboiler condenser

Type U-tube U-tube U-tube thennosyphon U-tube
Medium
-tube si de CH4 H2 propylene propane propylene
-shell side LP steam propylene c.ooling water LP steam chilled water
Capacity
transferred heat 49.8 349.5 12710 253285 145989.5
[MJ/h]
Heat transfer 0.646 16.7 637.6 1247 10211

area [mZ]
Number
-serial
-parallel
Pressure abs./eff.
[bar]
-tube si de 6.0 20.0 20.0 20.6 19.1
-shell side 3.0 21.0 1.0 3.0 1.0
Temperature
in/out [0 C]
-tube si de -149.0/20.0 -148 .0/36.9 45 .6/36.9 59.8/72.3 46.4/23 .0
-shell side 190.0/133.5 45.9/43 .6 19.9/39.9 190/133.5 5.0/40.0
Special material tubes: tubes:

stainless steel stainless steel
Other
26
A.Q.Qaratus Soecification List for heat exchangers and furnaces

Apparatus No. H12
Name heater
Type U-tube
Medium
-tube side propane
-shell side LP steam
Capacity
transferred heat 144.4
[MJ/h]
Heat transfer 0.785

area [m 2]
Number
-serial
-parallel
Pressure abs./eU.
[bar]
-tube side 2.2
-shen side 3.0
Temperature
in/out [0 C]
-tube si de 59.8/85.9
-shen side 190.0/133.5
Special material
Other
27
AI1J2aratus S.Qecification List for pum.Qs , blowers and compressors

Apparatus No. P6 P7 Pil
Name pump reactor pump stream pump tower

recycle to tower recycle
Type centrifugal centrifugal centrifugal
Medium propylene propylene propylene
Capacity [ton/hr] 491.1 50.2 816.9
Density [kg/m 3] 462.4 462.9 506.8
Pressure
abs./ eff..[bar]
suckfpress 20.0/20.3 19.0/19.4 18.5/19.1
Temperature
in/out [0 C] 459145.9 319/319 23.0/23.0
Power [kW]
-theoretical 2.95 1.20 26.9
-practical 3.47 1.54 31.6
Number
-serial
-parallel
Special material
Other
28
7 Process Control
The aim of the process control is to cope with all external disturbances. The control system
consists of two parts: the niaterial balance control and the product quality control. Each is
designed separately, as if they did not interact with each other. The material balance control
system is called on to compensate for very low frequency disturbances (e.g. plant management
decisions for changes in the production rate once a week or month). On the other hand, the
product quality control system is called on to secure the operation of the plant against higher-
frequency disturbances (once every half a minute, hour or day). The material balanee control
system can be designed by using steady-state bal anc es only, while the product quality control
system is designed by also considering the dynamic behaviour of the various units. The
material balanee and product quality control do not cover all operating aspects of a complete
plant. One of these missing aspects are the startup and shutdown of a plant.
7.1 Apparatus control
Reactor
The temperature in the reactor is controlled by the cooler in the propylene recycle stream. The
monolith reactor has an intern al recycle of hydrogen. The pressure in the reactor depends on
the amount of hydrogen present. Therefore, the pressure is controlled with the hydrogen feed.
The liquid level at the bottom of the reactor is controlled in order to prevent contact of the
liquid with the monolith blocks. The expected convers ion is achieved by control of the
recycle flow.
Distillation Column
The column temperature is controlled by the duties of the reboiler and the condenser. The
level and the pressure of the condenser's accumulation drum are controlled by the reflux flow
to the column and the vapour outlet. This is done using valves. The liquid level in the splitter
is controlled by a valve in the bottom product stream.
Pumps and heat exchangers

Pumps are pressure controlled. To provide for the pumps to run at a fixed speed and to supply
an output of near constant volume, a by-pass control is used. The heat exchangers are
temperature controlled. The temperature of a flow is controlled by varying the flow of the
cooling or heating medium.
7.2 Time constants
The temperature control generally has great time constants because of the following two rather
slow processes: heat transfer between recycle mixture and temperature sensor, and heat
transfer between cooling water and recycle mixture. The overall response will be sluggish so
a PID controller would be the most appropriate, because it allows high gains for fast responses
without undermining the stability of the system. The composition control shows a similar
situation to that of the temperature control. Very slow response caused by slow composition
sensors make a PID controller the most appropriate. The control of pressure and level has a
smaller time constant. There is a direct effect with fast response. A proportional controller is
satisfactory .
29
7.3 Start up and shut down
The control system of the plant must pennit smooth, safe and relative fast startup and
shutdown of the plant's operation. Normally this cannot be accomplished by the material
balance or product quality controllers alone, and additional control loops are needed. The
design of a startup or shutdown control system is beyond the scope of this process design. The
startup is relatively simple because of the structure of the monolith which enables the mixture
to react even with a small feed. The hydrogen feed has to be very sm all to obtain a low
convers ion and to enable the system to build up the recycle. Next, the hydrogen feed and the
cooling-water feed are increased. The startup is also in an other way simple because of the
fact that the feed already consists of 92 % propylene. This makes the startup of the distillation
column relative simpie. The shutdown is similar but now the other way around: the hydrogen
feed will be decreased and thus also the cooling-water feed in the reactor recycle, while trying
to maintain the column feed at the steady state level.
30
8 Process Safety
The potential fire and explosion hazards of the process are evaluated by calculating the Dow
Fire and Explosion Index for the main process units. The index is based on the nature of the
process and the properties of the materials. The calculations for the reactor, the column and
the flasher are listed in Appendix VI. It is found that the reactor has the largest risk, because
of the great stream entering it and because of the exothermic reactions.
A Hazard and Operability Study (HAZOP) is performed to systematically check the effects
of deviations from intended operating conditions (Appendix VI).
Table 4: MAC-values and explosion limits [6].

Compound MAC-value Explosion limit
[ppm, mgfm2 ] [vol % in air]
Hydrogen 4-76
Methane 5-16
Propylene 2-11
Propane 1.7-9.5
Methylacetylene 1000, 1650 1.7
Propadiene 3.1-12
MA+PD 1000, 1800 2-12
It is recomrnended to place everywhere on the plant terrain special sensors to ensure th at any
leakage in the apparatuses or piping can be detected directly. Also a extensive sprinkler
installation and good fire aid should be available because of the low explosion limit of all
compounds.
31
Selective Hydrogenation of MAPD present in the C] Naphtha Cut
9 Economics
All calculations are listed in Appendix VII.
9.1 Production costs
The production costs consist of direct and indirect costs. The direct costs are the sum of
production dependent costs, variabie cost and invstments costs. The indirect costs consist of
overhead, terrain, safety etc. The model for the calculation of the production costs is:
(24)
in which:
KT = total costs [Mfl/yr]
Kp = production volume dependent costs [Mfl/yr]
KL = semi variabie costs [Mfl/yr]
KI = investment dependent costs [Mfl/yr]
In this model, the indirect costs are accounted for by the factors 1.13,0.13 and 2.6. They are
from the "beste model" [40]. The factor 0.131 is a factor conceming the capital charge for a
lifetime of 15 years and an interest of 10%.
9.1.1 Production volume dependent costs
The production volume dependent costs can be calculated as follows:
(25)
in which:
Vj = costs of base chemicalor utility i per ton [Mfl/ton]
qj = amount of i needed [ton/ton]
9.1.2 Labour costs
For a continuous process, based on 350 kfl/labour position, the labour costs can be calculated
from:
K L = 32NCO24 (26)
in which:
N = number of steps [-]
C = capacity [kton/yr]
32
The process consists of two steps: reaction and distillation.
9.1.3 Investments costs
The total investments of a plant can be divided into four groups:
KI = Is+IH+IL+Iw (27)
,
=
j~mvestments m
. .
pro ce ss uruts
[Mfl]
(64% of total)
= investments in si de apparatuses [MflJ- (16% of total)
= investments in overhead [Mfl] (14% of total)
= investments in work capital [Mfl] (6% of total)
There are several models to estimate the investments based on IB. The methods of Zevnik-
Buchanan-Jansen, Taylor and Wilson are used. These methods calculate I B in k$.
Zevnik-Buchanan-Jansen method
In this method the investments depend on the process-capacity and complexity of the different
process units.
N[
Is = 0.1 Cl L c0 p m j
(28)
j=l
in which:
Cl = C.E plant cost index [-] = 382.4 [5]
NI = number of functional units [-] = 2 (reactor and column)
Cf = complexity factor of the functional unit [-]
P = unit capacity [ton/yr]
m = degression exponent [-] = 0.6
The complexity factor can be found from:
C = 2 * loCF;+Fp+F~ (29)
f
Values for the temperature factor (Ft), the pressure factor (Fp) and the material factor (Fm) are
found in Montfoort [40].
Taylor method
The Taylor model [40] is based on process steps, not on the number of apparatuses.
C
I = 71 f pO.39 ~ (30)
B 300
33
Selective Hydrogenation of MAPD present in the C] Naphtha Cut
in which:
P = plant capacity [ktonjyear]
Cr,T = EPE cost index [40] [-]
f = costliness index [-]
(31)
in which
N = number of process steps [-]
Si = complexity score for step i [-]
Values for Si are found from Montfoort [40] and are listed in Appendix VII.
Wilson method
This method is based on the number of all apparatuses, exc1uded the pumps.
(32)
in which
f = investment factor [-]
N = number of apparatuses without pumps [-]
AUC = average unit cost [k$]
Fp = pressure factor [-]
Fm = material factor [-]
Ft = temperature factor [-]
Values for f, Fp, Fm, Ft, and AUC are found in Montfoort [40].
For the three calculated values of Ia an exchange rate of 1.6 flj$ is taken. In Table 5, the
results of the different la's and the average value of Ia are listed.
Table 5: Values of Ia for the three different methods.

Method Ia
[Mfl]
Zevnik-Buchanan-Jansen 104.4
Taylor 57.9
Wilson 167.0
Average 109.8
Using the average Ia the total costs (KT) are: 235.42 Mfljyr. In Table 6 the incomes are listed.
34
Table 6: Incomes.
Product Production rate Price Incomes
[tonfhr] [ft/ton] [MlliE]
Propylene 47.02 640
""
1(240.7 )
Propane 2.93 240 ~
Fuel gas 0.31 250 0.6
Total 247.0
The profits can be calculated with: (Incomes - Kr)= 11.6 Mft/yr.
This value strongly depends on the costs of the raw propylene, of which no exact value is
known. A value of 350 ft/ton is assumed. In Figure 7 the dependence of the profits on the raw
material co st is shown. (Data in Appendix VIII).
Profits [MflIyr]
40 r--------------------------------,
30
20
10
o ~--------------~------~~----~
- 10
-20 l...-_ _ _ _ _ _ _ _ _ __ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _--.J
300 320 340 360 380 400

Raw propylene eost [flIton]
Figure 7: Dependence of the profits on the price of

raw propylene.
9.2 Economie Criteria
The purpose of economic criteria is to give a quick overview in order to decide whether to
start a project or not. There are several ways to calculate the rentability in which different
parameters are counting. Most usual is the ratio between the exploitation and the investments.
Examples are the Pay Out Time (POT) and the Return On lnvestments (ROl). Important is
how to defme the exploitation. When this is taken into account the method is dynamical, like
the Intemal Rate of Return (lRR), otherwise the method is static. The project time doesn't play
a role within the static method, it does within the dynamical method.
35
9.2.1 Pay Out Time (POT)
The POT is defmed as the number of years needed to pay back the original investments. The
original investments are the depreciabie capital investments. Interest and taxes are not
considered; this makes the POT more a risk ratio, which gives information about how long
the investments are risky, and makes it less a rentability ratio.
The POT is calculated with the next equation:
lp
POT = - - - - - - - (33)
expJoitation smpJus
exploitation surplus = incomes - Kp - 2.6 KL [Mfl/yr]

lp = Is + IH [Mft]
A value of 2.8 years is calculated. According to the rentability criterium, the lifetime of the
project has to be at least tree times the POT, that is 8.4 years. With a lifetime of 15 years, this
criterium is fulfilled .
9.2.2 Return on lnvestment (ROl)
The return on investment is the ratio of the annual profit and the total investments.
The ROl has some disadvantages like: na compensation of value of money and na variation
of incomes and costs in time (these are the market influences). Therefore, the ratio is often
used in preliminary design to compare similar processes with similar lifetimes.
The ROl can be calculated as follows:
ROl = Profits * 100% (34)

lp+ lw
A value of 12.2% has been calculated. Based on an ROl of 10% a minimum product price of
634 ft/ton is found. The actual product price is 640 ft/ton, which is very close to the minimum
product price.
9.2.3 Internal Rate of Return (IRR)
The IRR is a dynamic method in which the cashflows, including the investments, are
evaluated over the lifetime of the project with a return percentage r resulting from the sum
of the discounting cashflows to be zero. The value of r is the economical part of the method.
The basic idea is the investigation of the annual cashflow in projects with the same value of
r. Disadvantages of this method are: the comparison with several projects takes a lot of time
and two projects with different lifetimes are not directly comparable.
A value of 8.6 % is calculated.
36
10 Conclusions and Recommendations

10.1 Conclusions
The plant for the selective hydrogenation of methylacetylene and propadiene using a monolith
reactor, has an annual production of 376 kton polymer grade propylene (99.6% purity) when
it operates 8000 hfyr. The product yield is 0.94 ton product/ton raw material and the propylene
yield is 1.02 ton propylene in product/ton propylene in raw material.
If the raw propylene price is 350 fl/ton, an annual profit of 11.6 Mfl can be achieved. The
profits depend very much on the raw propylene price, of which a exact price is not known.
It can be concluded that this process has no bad impact on the environment because no
streams are purged. However, much cooling water and steam is needed, so the process is a
big energy consumer.
10.2 Recommendations
From this design no conclusion can be drawn about whether a monolith reactor or a trickle
bed reactor is recommended. That is because not enough is known about the costs of a trickle
bed reactor and because the model used to describe the monolith reactor is too much
simplified and too many exact values of parameters are not known. It is recommended to do
some research on these parameters, especially the kinetics and the behaviour of hydrogen in
propylene. Advantages of a monolith reactor in this design are the low pressure drop, so no
recompression is needed, and the absence of hot spots, which makes the reactor operate safer.
Because the profits of this design are very much dependent on the raw propylene price, it
should be recomrnended that a good knowledge of market situation is available. When this
price is too high, the plant should not be built.
Normally hydrogen will not be delivered as a liquid at such low temperatures (l09 K).
Therefore, the removal of methane in the flasher should be reconsidered. Removal with aid
of a gas separation membrane can then be a solution. With a membrane, a better separation
can be achieved, so the light ends removal at the top of the distillation column may not be
necessary then. Now, light ends removal in the distillation step is a expensive operation
because of the chilled water needed.
37
Nomenclature
specific area of the gas phase m 2/m 3

active tray area m2
total column cross section area m2
area occupied by dOWllcomer m2
total hole area m2
average unit cost k$/yr
parameter for the Smoker equations
c parameter for the Smoker equations
C capacity kton/yr
Cf complexity factor of the functional unit
C H2 concentration of hydrogen in the gas phase mole/m3
C H2 * concentration of hydrogen on gas-liquid interface mole/m3
CH2,bulk concentration of hydrogen in the liquid bulk mole/m3
Cl C.E. plant cost index
CIT EPE cost index
CMA concentration of methylacetylene mole/m3
Cp,L overall heat capacity of the liquid J/mole/K
Ctr capacity coefficient mts
Ct / corrected capacity coefficient mis
D distillate flow rate mole/s
deo I column diameter m
dh hole diameter mm
Ea activation energy J/mole
Eeol overall column efficiency
f costliness index
Fm material factor
Fp pressure factor
Ft temperature factor
H Henry coefficient of hydrogen in propylene bar m3/mole
heol total column height m
hTB height between top and bottom tray m
IB investments in process units Mfl
lp IB+IH Mfl
IH investments in side apparatuses Mfl
.-'
IL investments in overhead Mfl
lw investments in work capital Mfl
k parameter for the Smoker equations
3
~ specific reaction ra te m reaetojkg/ s
1<:os mass transfer coefficient mis
KI investment dependent costs Mfl/yr
KL semi variabie costs Mfl/yr
Kp production volume dependent costs Mfl/yr
KT total costs Mfl/yr
L reflux flow rate mole/s
lp hole pitch mm
Lw weir length m
38
m degression exponent
m parameter for the Smoker equations
MG gas mass flow rate kg/s
ML liquid mass flow rate kg/s
Mw molecular weight g/mole
N number of theoretical trays
N number of process steps
N number of apparatuses without pumps
Nco! number of actual trays
Nh number of holes per plate
NI number of functional units
Nr number of theoretical trays in the top section
Ns number of theoretical trays in the bottom section
P plant capacity kton/yr
P reactor pressure bar
P unit capacity ton/yr
Pr ratio operating gas velocity/uG,max
qi amount of i needed ton/ton
R actual reflux ratio
R gas constant J/molefK.
reaction rate of methylacetylene 3
r MA mole/m reactor
~in minimum reflux ratio
Si complexity score for step i
T temperature K
Tb .boiling point C
Ts tray spacing m
u superficial fluid velocity mts
uG,max maximum, allowable superficial gas velocity mts
ly maximum design vapour velocity mts
Vi costs of base chemicalorutility i per ton Mfl/ton
x mole fraction propylene in liquid phase
XB mole fraction propylene in bottom stream vapour phase
XD mole fraction propylene in liquid phase in distillate
x'o parameter for the Smoker equations
x' n parameter for the Smoker equations
y mole fraction propylene in vapour phase
YH2 mole fraction of hydrogen in the gas phase
Z monolith length parameter m
ZD mole fraction propylene in distillate
Zp mole fraction propylene in feed
ex relative volatility
p parameter for the Smoker equations
ilH r310 reaction enthalpy at 310 K kJ/mole
il~MA reactionenthalpy of the hydrogenation of MA kJ/mole
ilHrPD reaction enthalpy of the hydrogenation of PD kJ/mole
ilHr,pp reaction enthalpy of the hydrogenation of propylene kJ/mole
Ecat porosity of the catalyst m3 /3
cata!~Sl m reactor
1lliquid liquid viscosity Ns/m
39
V H2 total reaction stoichiometrie coefficient of H 2

V MA stoichiometrie coefficient of methyIacetyIene
V pD stoichiometrie coefficient of propadiene
V pp stoichiometrie coefficient of propylene
Pcat catalyst density kg/m3
Pa gas phase density kg/m3
PL liquid phase density kg/m3
Pliquid Iiquid density kg/l
Pl,mole moie density of the liquid moIe/m3
Pv vapour density kg/m3
cr surface tension NIm
40
References
1 Boiteaux, J.P., Cosyns, J., Derrien, M., Lger, G., Hydrocarbon Processing, 63, 4, p.
51-59, 1985.
2 Bond, G.C., Wells, P.B., Journalof Catalysis, ~, p. 65-73, 1965.
3 Bond, G.C., Sheridan, J., Trans. Faraday Soc., 48, p. 651-658, 1952.
4 Chem. Eng., 90, 10, p. 37, 1983.
5 Chemical Engineering, november 1995.
6 Chemiekaarten, SHD Tjeenk Willink, NIA, VNCI, Alphen aan den Rijn, 1991.
7 Coulson lM., Richardson, lF., Sinnott, RK., Chemical Engineering, vol. 6,
Pergamon Press, Oxford, 1991.
8 Cybulski, A., Moulijn, J.A., Cata!. Rev. - Sci. Eng., 36, 2, p. 179-270, 1994.
9 Derrien, M.L., Stud. Surf. Sci. Cata!., 27, p. 613, 1986.
10 Derrien, M.L., Andrews, J.W., Bonnifay, P., Leonard, J., Chemical Engineering
Progress, 70, 1, 1974.
11 Douglas, J.M., Conceptual Design of Chemical Processes, McGraw-Hill Book CO.,
Singapore, 1988.
12 Dow's fire & explosion index, hazard classification guide, 6th ed., American Institute
of Chemical Engineers, New York, 1987.
13 Edvinsson R, Monolith Reactors in Three-Phase Processes, Bibliotekets Reproservice,
GtRborg, 1994.
14 EthJfJ'le & propylene, 1991 ed., Reed Telepublishing Ltd., London, 1991.
15 Finco, M.V., Luyben, W.L., Polleck, R.E., Ind. Eng. Chem. Res., 28, p. 75-83, 1989.
16 Finelt, S., Hydrocarbon Processing, 58, p. 95-98, 1979.
17 Fogl, T.H.A., Selective hydrogenation of the C2, C3 and C4 fractions from steam
cracking of naphta, literature study, 1995.
18 Funk, E.W., Prausnitz, J.M., AIChE Journal, 17, 1, p. 254, 1971.
19 Gallant, RW., Physical Properties of Hydrocarbons, vol. 1, Gulf Publishing
Company, Houston, 1970.
20 Grievink, J., Luteijn, e.P., Thijs-Krijnen, M.E.A.M., Reader Handleiding
fabrieksvoorontwerp, 1994.
21 Hahn, A., Chaptal, A., Sialelli, J., Hydrocarbon Process., 54, 2, p. 89-92, 1975.
22 Harmens, A., J. Chem. Eng. Data, 30, p. 230-233, 1985.
23 Howat, C.S., Swift, G.W., Ind. Eng. Chem. Process Des. Dev., 19, p. 318-323, 1980.
24 Hsu, S., Hydrocarbon Processing, 66, 4, p. 43-44, 1987.
25 Huang, W., Chou, C.C., Hydrocarbon Processing, 59, 9, p. 223-227, 1980.
26 Irandoust, S., Andersson, B., Cata!. Rev. - Sci. Eng., 30, 3, p. 341-392, 1988.
27 Kirk-Othmer, Encyclopedia of Chemical Technology, vol. 9, 4th ed., John Wiley &
Sans, Inc., USA, 1994.
28 Kister, H.Z., Distillation Design, McGraw-Hill, Inc, New York, 1992.
29 Kirk-Othmer, Encyclopedia of Chemical Technology, vol. 19, 3rd ed., John Wiley &
Sons, Inc., USA, 1982.
30 Knunyants, I.L., Mysov, E.I., Kinetics and catalysis, li, p. 708-713, 1967.
31 Krnig, W., Hydrocarbon Processing, p. 121-126, March 1970.
32 Kumar, R., Golden, T.C., White, T.R, Rokicki, A., Separation Science and
Technology, 27, 15, p. 2157-2170, 1992.
33 Lide D.R, Handbook of Chemistry and Physics, 76, CRC Press Inc., New York,
1995-1996.
41
Selective Hydrogenation of MAPD present in the Cj Naphtha Cut
34 Mann, RS ., Kuhlbe, K .C., Can. 1. Chemie, 47, 2, p. 215-221, 1969.

35 Mann, RS., Lien, T.R, Journalof Catalysis, 15, p. 1-7, 1969.
36 Mann, RS., Naik, S.C., Canadian Journalof Chemistry, 45, 10, p. 1023-1030, 1967.
37 Mazid, M.A., Rangarajan, R., Matsuura, T., Sourirajan, S., Ind. Eng. Chem. Process
Des. Dev., 24, p. 907-913, 1985.
38 Mizan, T.l., Li, J., Morsi, B.I., Chang, M.Y., Chemical Engineering Science, 49, 6, p.
821-830, 1994.
39 Momoh, S.O., Separation and purification methods, 20, 2, p. 115-161, 1991.
40 Montfoort, A.G., Reader De chemische fabriek, deel IT, 1989.
41 Montfoort, A.G., Reader De chemische fabriek, deel 1B, 1989.
42 Montfoort, A.G., Reader De chemische fabriek, deel IA, 1989.
43 Moulijn, J.A., Makkee, M., Diepen van, A.E., Reader Process Technology, 1994.
44 Oluji, Dr. Z., Reader Scheidingsprocessen Il, deel I, 1993.
45 Pan, c.Y., Habgood, H .W., Ind. Eng. Chem. , Fundam., 11, 4, p. 323-331, 1974.
46 Sie, S.T., Reader Petroleumconversie, 1992.
47 Smith J.M . and Ness van, H.C., Introduction to chemical engineering thermodynamics,
4th ed., Me Graw-Hill Book Co., Singapore, 1987.
48 Stephanopoulos, G., Chemical process control, Prentiee-Hall, Inc., New Jersey, 1984.
49 Stern, S.A., Wang, S .-c., Journalof Membrane Science, 1., p. 141-148, 1978.
50 Tyreus, B.D., Luyben, W.L., Hydrocarbon Processing, 54, p. 93-96, 1975.
51 Upchureh, lA., Oil & Gas Journal, p. 58-63, Mar. 1992.
52 Wankat, P.C., Separation in Chemical Engineering. Equilibrium staged separations,
Elsevier Science Publishing Co., Inc., New York, 1988.
53 Williarns, R., Katz, O.L., Ind. Eng. Chem., 46, p. 2512-2520, 1954.
54 Winkle van, M., Todd, W.G., Chemical Engineering, p. 136-148, 1971.
55 Yoshida, N., Hirota, K., Bulletin ofthe Chemical Society of Japan, 48,1, p. 184-190,
1975.
42
Appendix I
Description of the assignment.
Designers Sandra Hornmerson

Arnoud Meyer
EveIien Nijman
Ton Xie
Supervisor A. Stankiewicz
Period October 1995 - January 1996
Selective Hydrogenation of Methylacetylene (MA) and Propadiene (PD) present in the

C 3 Naphtha Cut.
During the steam cracking of naphtha for the production of ethylene, C3 hydrocarbons are .
formed as by-products. They are removed from the process as the top product of the
depropanizer (the C3 cut). This C3 cut consists mainly of propylene, but also contains some
methylacetylene (MA), propadiene (PD) and propane.
To produce propylene of sufficient purity for polymerization, the MAPD content has to be
reduced to 10 ppm. This is done by selective hydrogenation to propylene. As a negative side
effect, some propylene will also be hydrogenated to propane which decreases the propylene
yield. ~ .
The propane content of polymer grade propylene may not exc ed 0.4 and therefore the
propane is removed by distillation (pP splitter). It is considered to De dangerous to remove
the MAPD from the feed directly in the column, because of explosion danger of MAPD in
high concentrations.
The aim of this project is to design an industrial plant for the catal tic hydrogenation of
MAPD in the C3 cut, with a capacity of 50 tons C3 per hour and produ ing propylene of 99.6
% purity. The reaction will be carried out in the liquid phase in a gas-l"quid monolith reactor.
The performance of this reactor will be compared to that of an alrea y existing triclde bed
reactor.
43
r----------------------- - ---,
r------------- - -----------~----------------,

CHIll.ED WATER'

PROPYLENE F1JEL GAS
COOUNG WATER
H 2 -<D--{Xl ~ C d
PROPYLENE ::n
. o
~
Vl
L. _ _ _ _ _ _ _ _ _ _ J
=r
(1)
~
~
LP STEAM
r

[ ~
~
~
'"<:j ::s
a
-
Q.
() ~.
(1)
~
Vl
,....
()
F1JEL GAS =
~
TO STEAM CRACKER
LP STEAM
V 1 GAS-UOUtO SEPARATOR FLOWSHEET FOR THE SELECTIVE HYDROGENA TION OF MAPD

H 2 HEATER
H J HEA TEXCHANGER IN THE C3 NAPHTA CRACKING CUT W1TH A MONOLITH REACTOR
R 4 MONOUTHtC REACTOR
H 5 COOLER
P 6 PUMP A.D. Hommerson
P 7 PUMP A. Meyer
T 6 PP SPUTTER LJ. NI)"non
H 9 REBOtLER
H 10 CONDENSOR T. XI.
P 11 PUMP FVO No. 3156
H 12 HEATER
VlJ TOP ACCUMULATOR
STREAM NUt.mER 1273 1 TEMPERATURE K CV PRESSURE BAR A
t
(Appendix II)
Thermodynamic values
Table 7: Thermodynamic values [7,19] .

Component 11 Hvap, 298 11 Hf ,298 Cp
[kJ/mole] [kJ/mole] [J/mole/K}
H2 0.904 0.000 28.9
propylene 14.4 20.4 63.5
propane 14.7 -104 73.1
MA 16.4 186 60.0
PD 17.1 192 58.5
C+
6 29.5 -41.7 131
45
(Appendix TI)
Input/output efficiency
42.4 3.37 2.36
CHILLED I COOLING LP STEAM I

WATER 1 WATER
1 FUELGAS
... 0.007
0.006
H2
- ......
PROPYLENE
1.00
1.06
FEED
...... CRACKER GAS
0.062
46
Appendix 111
Streamfcomponent status
Tabie 8: Streamjcomponent status

Stream no. 1 2 3 4 5
Components M [tonfh] M [tonfh] M [tonfh] M [tonfh] M [tonfh]
H2 0. 14 /1- ~ 0.13 0.01 0.01 0.01
CH4 0.12 ; '1.0 ~ 0.06 0.07 0.07 0.07
propylene
o 0'1
I
propane o O'a}
MA
PD
C6+
Total 0.26 0.19 0.07 0.07 0.07
Stream no. 6 7 8 9 10
H2 . 0.13 0.00 0.00
CH4 0.06 0.55 0.62

propylene 46.00 46.00 508.09 509.32
propane 2.00 2.00 28.92 29.67
MA 1.10 1.10 1.10 0.00
PD 0.90 0.90 0.90 0.00
C/ 1.47 1.62
Total 50.00 50.00 0.19 541.05 541.24
47
(Appendix lIl)
Tabie 8: Stream/component status (continued)

Stream no. 11 12 13 14 15
H2 0.00 0.00 0.00 0.00 0.00
CH4 0.56 0.56 0.50 0.56 0.56
propylene 462.09 462.09 415.89 462.09 462.09
propane 26.92 26.92 24.22 26.92 26.92
MA 0.00 0.00 0.00 0.00 0.00
PD 0.00 0.00 0.00 0.00 0.00

C+
6 1.47 1.47
~ 1.47 1.47
Total 491.05 491.05 442.00) 491.05 491.05

'-----'"
Stream no. 16 17 18 19 20
H2 0.00 0.00 0.00 0.00 0.00
CH4 0.06 0.06 0.06 0.06 0.33
propylene 46.21 46.21 47.23 47.23 814.52
propane 2.69 2.69 2.75 2.75 2.18
MA 0.00 0.00 0.00 0.00 0.00
PD 0.00 0.00 0.00 0.00 0.00

C+
6 0.15 0.15 0.15 0.15
Total 49.11 49.11 50.19 50.19 817.03
48
(Appendix lIl)

Stream no. 21 22 23 24 25
H2 0.00 0.00
CH4 0.29 0.02
propylene 45.41 0.15 0.15 814.33 46.88
propane 787.24 2.63 2.63 2.18 0.13
MA 0.02 0.00 0.00 0.00 0.00
PD 0.14 0.00 0.00 0.00 0.00
C+
6 45.00 0.15 0.15
Total 877.81 2.93 2.93 816.8 47.03
Stream no. 26 27 28 29 30
H2 0.00 0.00
CH4 0.33 0.29
propylene 45.26 45.26 814.52 814.33 0.15
propane 784.62 784.62 2.18 2.18 2.63
MA 0.02 0.02 0.00 0.00 0.00
PD 0.14 0.14 0.00 0.00 0.00
C+
6 44.85 44.85 0.15
TotaI 874.89 874.89 817.03 816.8 2.93
49
(Appendix lIl)

Stream no. 31 32
Components M [tonjh] M [tonfh]
H2 0.00 0.00
CH4 0.04 0.04
propylene 0.20 0.20
propane 0.00 0.00
MA 0.00 0.00
PD 0.00 0.00
C
6
Total 0.24 0.24
50
Appendix IV
Specification forms of the apparatuses
Delft University of Technology Date: 01/12/1995
Chemical Process Technology Designers:
Sandra Hommerson
Evelien Nijman
S}2ecification Form Towers
Apparatusnumber: : T8
General characteristics
Function : distillation I extra~ti9R I aS9rf1ti9R I
Type of tower : f1a~l{ed I tray I sf1rayer I
Type of tray : ~/sieve/~1
Number of trays
- theoretical : 148
- actual : 166
Tray distance (HETS) : 0.61 [m] Tray material: s eel
~~
Tower diameter : 4.31 [m] Tower height: 106.4 [m] J 1>0 VI.-
Tower material : \.(~
Heating : ~ I 9f1eR steam I reboiler I
Operating conditions
Feed Top Bottom Side stream Reflux I

absorbent
Temp rC] 46.0 23 .0 59.8 46.0 23.0

Pressure [bar] 19.0 19.0 20.6 19.1 19.1
Density [kg/m3 ] 131 30.8 436 463 436
Massflowrate 50.20 0.24 2.93 47.02 816
[ton/h]
Composition mole wt% mole wt% mole wt% mole wt% mole wt%
% % % % %
H, 0.01 1.81
CH, 0.30 0.12 34.21 16.47 0.09 0.03 0.09 0.03
propylene 94.29 94.11 63.85 83.53 5.54 5.1 99.65 99.70 99.65 99.70
propane 5.24 5.48 0.13 91.63 89.8 0.25 0.27 0.25 0.27
MA 1ppm 1ppm 0.00 5.1
PD 9ppm 9ppm 0.02
C'
0.15 0.30 2.82
Design
Number of caps I Packing type :

sieve holes I : 62482 Packing material :
Active sieve area : 12.26 [m 2] Packing

-volume : [m 3]
Weir length : 3.02 [m] -Iength : [m]
-width : [m]
Diameter downcomer I -height : [ml
hole 1 _ _ : 0.43 [m]
51
(Appendix IV)

Chemica} Process Technology Designer:
Sandra Hommerson
S}2ecification Form Heat Exchanger

Apparatusnumber: H: 2 Number: serial/parallel
Function : heater fuel gas stream
Type : heat exchanger

~
aOdeOSeF
FebaileF
Configuration : flXed tubes fllate

flaatiog head
U-tube
dauble tube
plate
Position : horizontal / >,'eFtil:al

",-0 I
~
Capacity : 49.8 ~~~
Heat transfer area : 0.646
Overall heat transfer coefficient : 100.0 W/m 2rC
2,00 )(:o,b)( 10 0
Logarithmic temperature difference : 221.6 C
Number of passes tube side : 2 .
Number of passes shell side : 1
Correction factor LMTD : 0.97
Corrected LMTD : 214.1 C
Shell Side Tube side
F1uid LP steam CH 4
Mass Flow [ton/h] 0.021 0.073
Condensing/reboiling mass flow [ton/h] - -
Mean specific heat [J/kg0C] 2064.7 3584.0
Heat of vaporization [kJ/kg]
Temperature in [0C] 190.0 -149.2
Temperature out [0C] 133.5 20.0
Pressure [bar] 3.0 6.0
Material carbon steel stainless steel
FVO No.: 3158
52
(Appendix IV)

Chemical Process Technology Designer:
Sandra Hommerson
SQecification Farm Heat Exchanger

Apparatusnumber: H: 3 Number: serialfparallel
General characteris"tics
Function . : heater H2 gas stream

OOleF
~aadeaseF
FeBaiieF
Configuration : flXed tHBes fllate

flaatiag head
U-tube
daHBle tHBe
plate
Position : horizontal / ~'eFti~al
Capacity : 349.5 MJ/h

Heat transfer area : 16.7 m2
Overall heat transfer coefficient : 100 W/m 2 rC
Number of passes tube side : 2
Corrected LMTD : 58 .0 C
Fluid H2 propylene
Mass Flow [ton/hl 0.189 49.1
Condensing/reboiling mass flow [ton/hl - -
Mean specific heat [Jfkgo C] 9731.8 3220.7
Heat of vaporization [kJfkg]
Temperature in [0C] -149.0 45.9
Pressure [bar] 21 20
Material carbon steel stainless steel
FVO No.: 3158
53
(Appendix IV)

Sandra Hommerson
SJ2ecificatian Farm Heat Exchanger

Apparatusnumber: H: 5 Number: serialfparallel
General characteris'tics
Function : cooler recycle stream
Type : heat e~H;haRgeF

cooler
~eodeoseF
FebeileF
Configuration : flXed tubes plate

fleatiog head
U-tube
deuble tube
plate
Position : horizontal/ ,,'eFti~al
Capacity : 12710 MJ/h

Overall heat transfer coefficient : 600 W/m 2 rC
Fluid cooling water propylene

Mass Flow [ton/hl 158.6 491 .1
Mean specific heat [JfkgC] 4187.5 3212.4
Temperature in [aC] 19.9 45.6
Temperature out [aC] 39.9 36.9
Pressure [bar] 1.0 20
Material carbon steel carbon steel
FVO No. : 3158
54
(Appendix IV)

Sandra Hommerson
S.Qecificatian Farm Heat Exchanger

Apparatusnumber: H: 9 Number: serial/parallel
General characteriStics
Function : reboiler bottom stream
Type : heat e*ehanger

eoolet=
enElenser
reboiler
Configuration : flXeEl tubes piste

fleating hesEl
U-tube ther:mosyphon
de\Jble tHbe
fHate
Position : horizontal/ ',<eFth;al
Capacity : 253285 MJ/h

Heat transfer area : 1247 m2
Overall heat transfer coefficient : 600 W/m 2rC
Shell Side Tube si de
Fluid LP steam propane

Mass Flow [ton/hl 111 .0 876.1
Condensing/reboiling mass flow [ton/hl - 876.1
Mean specific heat [J/kg0C] 4288.0 3503.6
Heat of vaporization [kJ/kg]
Temperature in [0C] 190.0 59.8
FVO No.: 3158
55
(Appendix IV)
Delft University of Technology Date: 19/1211995

Sandra Hommerson
Soecification Form Heat Exchanger

Apparatusnumber: H: 10 Number: 2 seAal/parallel
Function : condenser top stream
Type : heat eJtehsflgeF

~
condenser
FeBeileF
Configuration : fiJted tUBes fllate

fleatiflg head
U-tube
euBle tUBe
fllate
Position : horizontal/ >,'eFtieal

Heat transfer area : 10211 m2
Logarithmic temperature difference : 11 .2 C
Number of passes tube side :6
Number of passes shell side :2
Fluid chilled water propylene

Condensing/reboiling mass flow [ton/hl - 408.2
Temperature in [0C] 5.0 46.4
FVO No.: 3158
56
(Appendix IV)

Sandra Hommerson
Specification Fonn Heat Exchanger

Apparatusnumber: . H: 12 Number: serialfparallel
Function : heater bottom stream

eooleF
eeREleRseF
FeBeileF
Configuration : fHteEl tuees piste

flestiRg ResEl
U-tube
Eleuele tuee
I*ate
Position : horizontal / >,teFtiesl

Number of passes tube side :2
Fluid propane LP steam

Temperature in [0C] 59.8 190
Pressure [bar] 2.2 3
FVO No.: 3158
57
Appendix V
Apparatus calculations of monolith reactor
Constants
Densities
catalyst [kg/m3] Pcat 2250
liquid [mole/m3] PI 1.15674 E+04
gas constant [J/mole/K] R 8.314
Parameters
activation energy [J/mole] ~ [~, 4.389 E+04
specific reaction rate [m3reactojkg/s] ka 6.43 E+05
superficial fluid velocity [mfs] u 0.4
E 0.085
molecular diffusivity [m2/s] Db 8 E-09
monolith channel diameter [m] d 9 E-04
film thickness [m] r 17.427 E-06
mass transfer coefficient [m/s] = Db / r kc,s 9.2 E-04
specific area of gas phase [m2/m 3] a 455
Stoichiometric coefficients
MA -1
H 2 =-(1 + 1/1.8+ 1/500) -1.556944
Reaction enthalpy of the hydrogenation reaction

MA [kJ/mole] -1.6573E +05
PD [kJ/mole] -1.7242E +05
PP [kJ/mole] -1.2439E +05
overall heat capacity of liquid [J/mole/K] 67.36
Henry coefficient H 1 E+05
58
(1--
Appendix V ~
- "0
>
(')"0
S(l)
Shortcut calculations distilIation column
o~ ::l0..
a. _.
::l ~
Feed (F) Top (0) Bodem (B
1 0.944196 0.055804
-5
Mole stream
Molefraction propylen z
Molefraction propane 1-z
0.946
0.054
0.996
0.004
0.1
0.9
[
1.09
o
......
Alpha
Ntot 141.8993606 ::r
~
0.944196 0.994101 ~
o Cl)
Calculation Rmln en R
((zO/z)-alpha*((1-z0)/(1-z)))/(alpha-1 ) 11.42343
Rmin
alpha/(1.0614 "alpha-0.4175) 1.474116
X
y log((zO/(1-z0)*((1-zB)/zB)"(z/(1-z))"(0.55*alpha)) 4.095919
1.468096
R/Rmin
Rmin"(R/Rmin) 16_n069
R
Calculation number of trays

1.08 alpha_B 1.1
alpha_T
Bottomsetlon
IQI2~~tIQn -0.0212958
0.262496 xO' zO-k
xO' zO-k
0.212496 xn' z-k -0.8672958
xn z-k
0.943728 m R/(R+i) 1.0033258
m R/(R+1)
0.056047 i zO/(R+1) -0.0003326
i zO/(R+1)
0.733504 k O<k<1 0.9672958
k O<k<1
1.05868 c 1+k*(alpha_B-1) 1.0967296

c 1+k*(alpha3-1)
3.589657 be m"c*(alpha_B-1 )/(alpha_B-m*c"2) -1.0301603
be m*c*(alpha_T-1 )/(alpha3-m*c"2)
In(((xO'*(1-be*xn'/(xn'*(1-be*xO'))))/in(alpha_T/(m"c"2: n.97881 Nbot In( ((xO'"( i-be*xn'))/(xn' (i-bexO')) )/ln(alpha_B/(m"c"2) 63.920552
Ntop
0.075498 ai m(alpha_B-1 ) 0.1003326
ai m*(alpha_T-1)
-0.13179 bi m+i(alpha_B-1 )-alpha_B -0.0967075
bi m+i*( alpha_T-1 )-alpha3
0.056047 c1 i -0.0003326
c1 i
1.012082 k1 (-bi +(ci"2-4"a 1"c1 )"O.5/2b1 0.9672958
k1 (-bi +(c 1"2-4 *a 1*ci )"O.5))/2*b 1
0.733504 k2 (-b1-(c1"2-4"a 1c1 )"O.5))/2bi -0.0034268
k2 (-bi-(c1"2-4"a i"c1 )"O.5))/2*bi
VI
\0
()r--
Appendix V Il)
-'"0
>-
()'"O
E..(1I
Shortcut calculations distillation column Il) ::s
a.
o 0.-
......
::s ~
Feed (F) Top (D) Bodem (B () -<
0'-"'
Mole stream 1 0.944196 0.055804 r
Molefraction propylen z 0.946
0.054
0.996
0.004
0.1
0.9

Molefraction propane 1-z 0.-
1.09
Alpha ~.
Ntot 141.8993606
D 0.944196 0.994101 (11
~
(11
Calculation Rmin en R '"1
Rmin ((zD/z)-alpha'((1-zD)/(1-z)))/(alpha-1 ) 11.42343

X alpha/(1 .0614alpha-0.4175) 1.474116
Y log((zD/(1-zD))*((1-zB)/zB)(z/(1-z))"(0.55alpha)) 4.095919
R/Rmin 1.468096
R Rmin'(R/Rmin) 16.77069
Calculation number of trays

1.08 alpha_B 1.1
alpha_T
Bottomsection
Topsection
0.262496 xO' zD-k -0.0212958
xO' zD-k
0.212496 xn' z-k -0.8672958
xn' z-k
0.943728 m R/(R+1) 1.0033258
m R/(R+1)
0.056047 i zD/(R+1) -0.0003326
zD/(R+1)
0.733504 k 0<k<1 0.9672958
k 0<k<1
1+k'(alpha_T-1) 1.05868 c 1+k'(alpha_B-1) 1.0967296

c
m'c'(alpha_T-1)/(alpha_T-m'c"2) 3.589657 be m'c'(alpha_B-1 )/(alpha_B-m'c"2) -1.0301603
be
In(((xO"(1-be'xn'))/(xn"(1-be'xO'))))/ln(alpha_T/(m'c"2: 77.97881 Nbot In(( (xO"( 1-be'xn') )/(xn"(1 -be'xO'))) )/In(alpha_B/(m'c"2) 63.920552
Ntop
m'(alpha_T-1) 0.075498 a1 m'(alpha_B-1) 0.1003326

a1
m+i*(alpha_T-1 )-alpha_T -0.13179 b1 m+i*(alpha_B-1 )-alpha_B -0.0967075
b1
0.056047 c1 i -0.0003326
c1 i
(-b1 +(c1"2-4'a 1'c1 )"O.5))/2b1 1.012082 k1 (-b1 +(c1"2-4'a 1'c1 )"O.5))/2b1 0.9672958
k1
(-b1-(c1"2-4'a 1'c1 )"O.5))/2b1 0.733504 k2 (-b 1-(c1"2-4'a 1'c1 )"O.5))/2b1 -0.0034268
k2
0\
o
Appendix V
Calculation column height
N theoritical N 149
Efficiency E 0.9
N actual Ncol N/E 165.55556
h between trays (m) h_TB Ts*(Ncol-1) . 100.37889

h above top tray (m) ht 1.5
h below bottom (m) hb 2.5
h skirt (m) hs 2
column height (m) h h_TB+ht+hb+hs 106.37889
Tray design
Number of holes Nh Fh*(Ah/Ap) 62482.330

Active tray area (m2) Aa (pi*d"2*0.25)-2* Ad 12.262
Weir length (m) Lw O.rd 3.018
Diameter downcomer (m) Dd 0.1*d 0.431
Fraction hole area Fh 0.9*(dh/lp)"2 0.100
Hole area Ah 0.25*pi*dh"2 0.000
Hole diameter dh 0.005
hole pitch lp 3*dh 0.015
Area downcomer Ad 0.08*Ac 1.168
Theta 130.396
Weir length/tray diam Lw/d Lw/d 0.700
Column area Ac 0.24 *pi*d"2 14.598
tray diameter (m) d 4.312
61
Appendix VI
Process safety
Table 9: HAZOP analyse of reactor section

Stream nr. Subject. Reason Consequence Management
Guide word
1 Flow Friction in the pipe I .Flow is decreasing, la)shut down the flow
system which causes pressure in the flash 1b)reaction ceases
NO or high pressure drop, decreases. lc)fix up a
LESS corrosion will take compressor
place. ld)c1ean the pipeline
2.Air leakage in the unit. 2a)alarrn sys. c10ses

If < 9.5 bar, explosion unit with
danger of gas mixture. quenching
2b)install a heat
exchanger
T Unit defect. H 2 stays in liquid phase. 3a)proper maintenance
Compo- Damage of 3.Impurity 3a)

nent demethanizer unit. 4.Refractory partic1es 4a)install filter sys.
MORE Flow Flow controller doesn't 5.0verflow, possible 5a)install a valve

and P work explosion danger 4a)
3,4,5 Flow Excessive flow of 5 5a)

MORE stream 1
Compo- Defect of flasher 3,4 3a),4a),

nent
T Unit defect 6.H 2 Ieakage, explosion la),2a),2b)

danger, flammable .
P higher T 6 la),2a),2b)
NO or Flow Friction, flasher defect, 1,2,6 la),b),c),d)

LESS higher T, plug in 7.higher concentration 2a),b)
pipeline. and heat accumulation.
2,8 Flow Excessive flow of 5 5a)

MORE stream 1
T Friction, flasher defect, 6 la)b)c)d)

higher T, plug in 7.higher concentration 2a),b)
pipeline. and heat accumulation.
p High T 6 la),2a),2b)
Compo- Damage of 3,4 3a),4a)

nent. demethanizer unit .
62
(Appendix VI)
Table 9: HAZOP analyse of reactor section (continued)
NO or Flow Friction, flasher defect, 1,2,6,7 1a),b),c),d)
LESS higher T in the flash, 2a),b)
plug in pipeline.
REVERSE Flow Steam failure, blocked 5,6,7 8a)Fit non- return

pipeline or plugs in the valve.
opening of reactor,
corrOSlon.
6,7 Flow Flow controler doesn't Higher pressure, excess 5a)

MORE work. liquid, less efficient.
T Unit defect friction, 6,7 2a),b)

higher T, plug in
pipeline.
P Flow controler doesn't Flow increases 5a)

work.
REVERSE Flow Steam failure, blocked 5,7 8a)

pipeline or plugs in the
opening of reactor,
corrOSlOn.
6,7,9 Flow Friction in the pipe Flow decreases, 1a),b),c),d)

NO or andP system which causes pressure in pipeline
LESS high pressure drop, decreases
corrosion will take
place.
Compo- Unit defect 3,4 3a),4a)

nent
11 Flow Pump is turning too fast Higher pressure, excess 3a, or pump
MORE andP or another reflux solvent, more efficient but rearrangement.
fraction. less product.
T Heat exchanger defect, 6,7 2a),b), water stream

friction, higher T, plug control
in pipeline.
NO or Flow Friction in the pipe Flow decreases, 1a),b ),c ),d)

LESS andP system which causes pressure in pipeline
high pressure drop, decreases.
corrosion will take
place.
REVERSE Flow Pump defect, steam 5,7 8a), shut down the
failure, blocked pipeline stream immediately
or plugs in the opening
of reactor, corrosion.
63
(Appendix VI)
Table 9: HAZOP analyse of reactor section (continued)
12,13,14 Flow Flow controler doesn't Higher pressure, excess Sa, reflux
MORE work, another reflux liquid, more efficient but rearrangement
fraction. less p!oduct.
P,T Flow overheated, 7 Water stream

friction, plug in the rearrangement.
pipeline.
NO or Flow Another reflux fraction, 1 1c),d)

LESS flow controler doesn't
work.
P,T Flow overcooled. Reaction rate decreases. Water stream

re arrangement.
AS WELL Flow Leakage Install new pipeline

AS
10 Flow, P Flow controler doesn't Higher pressure, excess Sa) or install a reactor
MORE work, reaction not liquid, not complete with long dimension.
complete. conversion.
T Internal recycling not Gas plug in the reactor 2a),b)

efficient, reactor effluent, liquid partially
overloaded with catalyst, vaporized.
heat emission not
efficient.
NO or Flow, P Flow controler doesn't 1,2 1a),b ),c),d)

LESS work, same as stream
2,3 .
T No rea ct ion at all or 3a), flow rate control

flow rate too high.
REVERSE Flow Steam failure, blocked 5,7 8a)

pipeline
Table 10: HAZOP analyse of distillation column section

19 Tand P The same as stream id. id.
MORE 12
Flow Reflux fraction or the id. 5)

same as stream 12
NO or Flow id. id. id.

LESS
64
21,26,27 T Too much stream to Bad separation Down stream
MORE the reboiler, the management or
reboiler defect, increase the number of
internal recycling not separation steps in the
efficient. column.
(Appendix VI)
Table 10: HAZOP analyse of distillation column section
NO or P,T Defect reboiler Down stream
LESS management.
Column P Steam failure, blocked Bad separation 1a,ld

MORE pipeline.
20 Flow Due to the high T More product stream Control flow and
MORE decrease T.
NO or Flow Lower T Less gas outlet Control flow and

LESS decrease T.
28 T Condenser doesn't Product stream stays in Change the condenser,

MORE work efficient or gas phase and more cooling water, or
more gas flow . vaporizes, less product apply pressure above
stream will be left. V13.
65
(Appendix VI)
Dow Fire and explosion index
Table 11: Calculation of the Dow Fire & Explosion Index.

Reactor Column Flasher
Material Factor (MF) 21 21 21
General process hazards
Base factor 1.00 1.00 1.00
Exothennic chemical reactions 0.30
Operation above flash point 0.30 0.30 0.30
Total (F1) 1.60 1.30 1.30
Special process hazards
Base factor 1.00 1.00 1.00
Toxic Materials 0.40 0.40 0.20
In flammabie range in case of equipment failure 0.30 0.30 0.30
Pressure 0.70 0.70 0.85
Low pressure 0.20 0.20 0.20
Total (F2) 2.60 2.60 2.55
Unit hazard factor (F! x F2 = F3) 4.16 3.38 3.32
Fire and explosion index (F3 x MF = F&EI) 87.4 71.0 69.6
66
Appendix VII
Economic calculations and tables
Tabie 12: Costs of base chemicals and utilities.

Product unit flow [unitfhr] price [fl/unit] costs [Mfl/yr]
C 3 cut ton 50 350 140.00
Hydrogen ton 0.188 1500 2.26
Cooling water H5 ton 159 0.1 0.13
Chilled water HIO ton 1993 0.5 7.97
Steam H2 ton 0.022 30 0.01
H9 ton 111 30 26.63
H12 ton 0.063 30 0.02
Electricity P6 kWh 3.47 0.13 0.0036
P7 kWh 1.54 0.13 0.0016
Pll kwh 31.6 0.13 0.0329
Total costs 177.06
Tabie 13 : Costs of monolith and catalyst.

unit amount needed pnce time in costs
[unit] [kfl/unit] use [yr] [Mfl/yr]
Monolith m3 12.86 35 12 0.0375
Catalyst kg 81.8 149 12 1.016
Total costs 1.05
67
()r....
Appendix VII ~
"'--0
:>
Caleulatlon proflts 0-0
Total eosts
Caleulatlon kp . g
Kp + KI+ KL 235.42 ~ ~ ~~
Kt (Mfl/yr)
Kp (kfl/yr) o"kp 201252.9321 Product flow (ton/hr) prlce (fl/ton) hours/year costs (MfI/yr8 x
KI (kfl/yr) b*(lb+lh+IL+lw) 28648.27949 C3 50 350 8000 140.00 -0 <:
KL (ktl/yr) c*(32*NL "P"0.24) 5517 .457276 H2 0.188 1500 8000 2.26 (3 Cl
1.13 Totol 142.26 ::tJ
a ii
b 0.261
2.6 Apparotus
e
vl"ql 178.10 Coollng capocIty (kW) tlow (ton/hr) prlee (fl/ton) costs (Mtl/yr)
kp (Mfi/yr)
100/64"lb1 109763.523 H5 3530.56 159 0.1 0.13
Ib (kfl/yr)
number of steps 3 HlO 40552.64 1993 0.5 7.97
NL
40c000 Totol 8.10
P (ton/yr) copoclty"hr /year
hr/year 8000
Steom (Iow pressure) flow (ton/hr) prlce (tl/ton) costs (Mfl/yr)
H2 0.022 30 0.01
Ineomes
H9 111 30 26.63
prlce fI/ton flow ton/hr Incomes Mfl/yr H12 0.063 30 0.02
produets
640 47 .021 240.74752 Totol 26.65
propylene (polymere grode)
propone 240 2.92807 5.6218944
methone 250 0.3115 0.623
246.9924144 Reactor volume monollth cost~ cotolyst costs costs (Mfl/yr)
Totol
R4 12.86 0.037 1.016048084 1.05
Incomes-totol costs 11.57375 Totol 1.05
Proflts(Mfi/yr)
Electrlclty cap (kW) power kWh/yr prlce tl/kWh costs (Mtl/yr)
P6 3.47 27760 0.13 0.0036
P7 1.54 12320 0.13 0.0016
Pll 31.6 252800 0.13 0.0329
Totol 0.0381
0\
00
n"""'
~ :>
Appendix VII -"Cl
(')"Cl
Calculatian investment casts .~
~ ::;
C. 0-
e ~.
TAYLOR ::;
S' <:
<: ~
Ib (kS/yr) k*f*P"0.39*CT /300 23161.21 Average investment costs (kfl/yr) ~'-'
(Ib, taylor+lb,zevnik+lb,wilson)/3 109763.52
k exchange rate factor 70.85714286
400 exchanging $ to fl 1.6
8g
P (kton/yr) plant capacity .....
f costliness index 10.16903 (')
932 e
EPE plant cost index
CT ~
ZE V NIK -B U C H A N A N-JANSEN
Ib (kS/yr) NZ*O.l *Cf*P"m*Ci 41751.93

Cf 2* 1O"(Ft+Fp+Fm) 2.726026012
NZ number of functional units 2
P (kton/yr) plant capacity 400
Ci CE plant cost index 382.4
m degression exponent 0.6
Ft temperature factor 0.0045
Fp pressure factor 0.13
Fm material factor o
WILSON
Ib (k$/yr) f * N W* auc * Fp * Ft * Fm * k 7751.935513

f investment factor 1.5
NW number of apparatuses 10
AUC (kS/yr) average unit cost 126943.3014
Fp pressure factor 1.02
Ft temperature factor 1.03
Fm material factor 1
k exchange rate factor 2.066666667
0\
\D
(Appendix VII)
Calculation costliness index
Table 14: Listing of complexity score and costliness indices.

Stream Throughput Reactionl Pressure 1 Multi Total Costliness
storage temp streaming score index
time
Feed 0 0 1 0 1 1.3
Recycle 4 0 1 0 5 3.7
Hydrogen -3 0 3 0 0 1
Process Unit
Reactor 0 0 1 0 1 1.3
Column 0 0 1 3 4 2.9
Total 10.2
70
or--.
Calculations economic criteria ~ :>
....... 'ij
o 'ij
.~
2.79704903
POT (yr) If/ expl .surplus
o~ ::l
a.o-
_.
If (Mfl) Ib+lh 87 .81081836
::l ><
incomes-kp-KL 31 .39409336
Expl.surplus (Mfl/yr) ~ <:
g~~
ROl Profits/(lf+lw)* 100% 12.26076136
Iw 0.06*ltot
If=lb+lh
6.5858
87 .81081836
2.
If

::l .
......
~
::1.
~
IRR
cash flow dcf di IRR
out in out in 0.086249361
jaar
o 103178 103177.7116
1 12518.89567 11524.88196 0.92059893
2 12518.89567 10609.794 0.84750239
3 12518.89567 9767.365009 0.780209794
4 12518.89567 8991 .825778 0.718260301
5 12518.89567 8277 .865192 0.661229665
6 12518.89567 7620.59384 0.608727322
7 12518.89567 7015.510536 0.560393722
8 12518.89567 6458.471494 0.515897861
9 12518.89567 5945.661948 0.474935019
10 12518.89567 5473.570028 0.43722467
11 12518.89567 5038.962712 0.402508563
12 12518.89567 4638.863682 0.370548953
13 12518.89567 4270.532943 0.34112697
14 12518.89567 3931 .448058 0.314041123
15 12518.89567 3619.286877 0.289105922
Total 103178 187783.4351 103177.7116 103184.6341
in/out ratio 1.82 1.000067093
Cash flow out (Mfl) Ib-Iw 103177 .7116

di -..l 1/((1 +IRR)lIcf,in
......
.
Appendix VIII
Graphics data .
Appendix VIII Data graphics
T abi e 15 Daat FIgure 5 T abi e 16 Daat FIgure 6 Tabi e 17 Data FIgure 7

Mololith length MA concentration Temperature RlRmin N(R+1) Price raw propylene Profits
rml l[mole/m3l IrKl 1.1 3859.116 l[fVkg] [MfVyr]
0 24.7 310 1.2 2839.223 300 34.17375
0.02 24.6927 310.0025 1.3 2605.438 310 29.65375
0.04 24.68531 310.0049 1.4 2532.095 320 25.13375
0.06 24.67793 310.0074 1.468 2521.494 330 20.61375
0.08 24.67055 310.0099 1.5 2523.505 340 16.09375
0.1 24.66317 310.0124 2 2788.566 350 11.57375
0.12 24.65579 310.0148 360 7.053746
0.14 24.64841 310.0173 370 2.533746
0.16 24.f)4103 310.0198 380 -1.98625
0.18 24.6336 310.0223 390 -6.50625
0.2 24.62627 310.0248 400 -11.0263
0.22 24.61888 310.0275
0.24 24.6115 310.0297
0.26 24.60412 310.0322
0.28 24.59674 310.0347
0.3 24.58936 310.0372
72

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FVO Nr.

Datum opdracht 06-10-1995

T U Delft Faculteit der Scheikundige Technologie en der Materiaalkunde

Technische Universiteit Delft

Datum opdracht 06-10-1995

The exothermic hydrogenation is carried out adiabatically in a monolith reactor, operating at

3 Process Structure and Process Flowsheet 4

4 Process Flowsheet and Apparatus Calculations 7

5 Mass and Heat Balance 21

6 Apparatus Overview and Specifications 25

10 Conclusions and Recommendations 37

Cr,,;..,;~ ""AAN- I' ..;"JJ ' t.- q4. t t-.r'~

Figure 1: Structure of the process

CH2=C=CH2 + H 2 ---> CH2 =CH -CH3 ~-+ 4 l ..-, lS ~,(Q ~~

The hYdrogen~l'Will be carried out in a monolith reactor. Advantages of such a reactor

Bec.use only D is a11~ t e reacto r product, it is assumed that the reactor

Hydrogen H2 2.02 -252.8 0.071 (-253C) 1.3

Methane2 CH4 16.04 -162.0 0.425 (-161 C) 2.0

Methylacetylene C=C-C 40.06 -23.2 0.706 (-50 C) 12.5

3 Process Structure and Process Flowsheet

No external H 2 recycle is needed because the

Demethanizer feed sy em implemented by naphtha cracking is used to provide the hydrogen

MA (1) + H 2 (g) propylene (1)

reaction (1): ilHr310 = -164 kJ/mole

4 Process Flowsheet and Apparatus Calculations

Table 3: Differences between TBR and MR [13].

cost low high

volumetrie catalyst 0.55-0.6 for conventional 0.05-0.25

extemal surface area 1000-3000 m 2/m 3 1500-2500 m 2/m 3

pressure drop high for small particles very low

mode of operation pseudo steady state inherently unsteady

superficial velocities liq: 0.005-0.05 mis liq: 0.03-0.15 mis

diffusion leng th 0.1(shell)-2.5 mm 50-150 \lm

Advantages of a MR compared to a TBR

Disadvantages of a MR compared to a TBR

4.1.2 Starting points for the reactor design

The following reactions take place:

The reaction rate of the hydrogenation of MA is given by [13, 34]:

According to Derrien [9] an approximation of the reactivity ratio of MA to PD and of PD to

To describe the Taylor flow, a very detailed model is necessary. To

Hydrogen transfer from gas to the liquid film :

The value of C H2 * can be found by:

Hydrogen transfer through the liquid film:

Mass balance over MA:

dT rMA Cv MA!:::.~U4 + VPD !:::.~PD+ v PP !:::.~pp)

4.1.4 Results and discussion

cma (mole/m3) T(K)

Figure 5: Decrease of the MA concentration and

4.1.5 Reactor evaluation

4.2.1 Determination of the number of trays

Based on a feed containing propylene and propane only:

Based on the actual column feed:

Por the top section:

Por the bottom section:

Xo = mole fraction propylene in liquid phase in distillate [-]

2400 ' - - - - - - - - - - - - - - - - - - - - - '

Figure 6: Determination of the optimum reflux .

4.2.2 Evaluation of the column

4.2.3 Column sizing

The colunm diameter is calculated using the following relations [44]:

The capacity coefficient is obtained fIOm:

Cu = 0.0129+0.1674 T.s+ FLdO.0063-0.2682 T)+Frd -0.008+0.1448 T) (15)

in which FLG is the liquid-vapour flow parameter:

F LO ML( Po)o.s (16)

-20 l...-_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _--.J