Styrene Production

Senior Design Final Report
Professor J.A. Sykes

May 12, 2006

By Team #7:
Larae Baker
Maxine Bent
Jonathan Bush
Mike Heslinga
Adam Jones

Abstract: A new process to produce styrene monomer is under development by Dow
Chemical and Snamprogetti. Team #7 has designed and simulated an industrial plant to
produce two billion pounds of styrene monomer per year. An advantage to the new
process is that it starts with a less expensive raw material, ethane, instead of ethylene.
The process has three key stages: 1.) A distillation reactor alkylates benzene and
ethylene to make ethylbenzene. 2.) A dehydrogenation reactor where ethylbenzene and
ethane are converted into styrene and ethylene respectively. 3.) A distillation train where
a purity of 99.93% styrene is achieved. Styrene can be produced at an estimated market
price of $0.99/lb with this process.
Table of Contents
1 INTRODUCTION..................................................................................................... 4
2 THE CHEMISTRY .................................................................................................. 4
2.1 ALKYLATION ....................................................................................................... 4
2.2 DEHYDROGENATION............................................................................................ 6
2.3 POLYMERIZATION................................................................................................ 7
3 OBJECTIVES........................................................................................................... 8
4 PROCESS DESCRIPTION..................................................................................... 9
4.1 DESIGN ALTERNATIVES ....................................................................................... 9
4.1.1 Styrene from Ethylene and Benzene.............................................................. 10
4.1.2 Co-Production of Styrene and Propylene Oxide .......................................... 10
4.2 AREA 100 ALKYLATION.................................................................................. 10
4.2.1 Equipment Design......................................................................................... 11
4.2.2 Catalyst Design............................................................................................. 13
4.3 AREA 200 DEHYDROGENATION ...................................................................... 13
4.3.1 Equipment Design......................................................................................... 14
4.3.2 Catalyst Design............................................................................................. 16
4.4 AREA 300 SEPARATIONS OF AROMATIC PRODUCTS ........................................ 17
4.4.1 Separations Train and Column Design......................................................... 17
4.4.2 Separations Inhibitors................................................................................... 20
4.5 AREA 400 LIGHT GAS SEPARATION ................................................................ 21
4.6 HEAT EXCHANGER DESIGN................................................................................ 22
4.7 PUMP, COMPRESSOR AND TURBINE DESIGN ...................................................... 23
4.8 MATERIALS OF CONSTRUCTION......................................................................... 24
5 ENVIRONMENTAL, HEALTH AND SAFETY ISSUES.................................. 25
5.1 ENVIRONMENTAL CONCERNS ............................................................................ 25
5.2 CHEMICAL HAZARDS ......................................................................................... 26
5.3 SAFETY HAZARDS.............................................................................................. 27
6 CONTROL DESIGN.............................................................................................. 28
6.1 CONTROL DESIGN ON AREA 100........................................................................ 28
7 ECONOMIC ANALYSIS ...................................................................................... 32
8 UNCERTAINTIES AND ASSUMPTIONS.......................................................... 34
9 FUTURE WORK.................................................................................................... 34

1 Introduction
Styrene is a precursor to many polymer products such as polystyrene, acrylonitile
butadiene styrene (ABS), styrene-acrylonitrile, and various styrene-butadiene
products. These materials are used around the world in a variety of ways including
food storage, packaging, and automobile parts.
1
The market for styrenics has seen
overall growth in the previous decade despite a recent down year. The market is
expected to recover and see large gains in the near future. Therefore, now is an
excellent time to join the market, particularly if current styrene production cannot
meet future demand.
2

The process of producing styrene is well established. It was first produced in the
1930s by I. G. Farben in Germay and Dow Chemical in the United States. Styrene
is a clear liquid at room temperature with an aromatic odor. It is currently sold with
a minimum purity of 99.8% but is more commonly produced at 99.93%. The price
of styrene remains largely dependant on the cost of its raw materials.
3

2 The Chemistry
Production of styrene requires two reactions, an alkylation and a dehydrogenation.
2.1 Alkylation
The alkylation is a basic Friedl-Crafts alkylation, where ethylene reacts with benzene
to form ethylbenzene by Reaction 1a:
3

(Rxn 1a)

This reaction is exothermic and takes place in a distillation reactor system that is
partially packed with catalyst. The benzene is in vapor-liquid equilibrium and it is
alkylated as it passes through the catalyst.
4
This alkylated product has a lower
boiling point than benzene and will therefore become the distillate product in the
column. The catalyst is a molecular sieve known as EBZ-500S available through
UOP, LLC. EBZ-500S minimizes the amount of byproduct, such as polyaklylated
and oligomerized products.
5
The polyalkylated products that are formed come off in
the bottoms of the distillation. They are sent to a transalkylation reactor to be
converted back to ethylbenzene by Reaction 1b:

(Rxn 1b)

The catalyst in this reaction is EBZ-100, also available through UOP, LLC.
Oligomerization products are caused by the partial polymerization of ethylene.
These may either come off the top of the column or aklylate with benzene to form
byproducts that include cumene, n-propylbenzene, butylbenzenes as well as other
heavy alkybenzenes. Other byproducts come from the raw materials; for example,
toluene and C
6
non-aromatics can be present in the benzene feedstock, up to
1000ppm and 2000ppm respectively. These can also be alkylated, and leave as a
bottoms product.
3
2.2 Dehydrogenation
The dehydrogenation occurs in a fluidized catalyst cracking reactor, or FCC.
6
An
FCC was chosen over other reactor systems because it has the advantage of
continuous catalyst regeneration. The catalyst is comprised of gallium oxide
(Ga
2
O
3
), platinum, iron oxide (Fe
2
O
3
), potassium oxide (K2O) and silica suspended
on alumina.
7
It is unique in that is used to simultaneously dehydrogenate ethane and
ethylbenzene via reactions 2a and 2b:

(Rxn 2a)

(Rxn 2b)

These reactions are highly endothermic. The energy for the reaction is provided by
the catalyst in the regeneration reactor, where it is heated to 660C upon decoking.
The catalyst needs to be decoked continuously because two side reactions occur that
form toluene, benzene and coke, as shown in Reactions 2c and 2d:

H
2

H
2

(Rxn 2c)

(Rxn 2d)

The coke deposits on the catalyst, reducing the number of active sites, and thus
lowering the conversion of the desired reactions, 2a and 2b.
8
Toluene can also lose
another carbon to become benzene. These reactions account for total of 3% loss in
conversion.
3
Reactions 2a and 2b are also highly selective with 90-94% and 90-93%
selectivities respectively.
9

Other byproducts in the dehydrogenation form from byproducts in the alkylation.
For example, dehydrogenated cumene becomes -methylstyrene and n-
propylbenzene becomes allylbenzene. Other byproducts include vinlytoluenes,
xylenes, ethyltoluenes, phenylacetylene, unconverted alkylation byproducts and
heavy aromatics. These byproducts are insignificant in terms of yield loss, but
greatly affect the cost of purification and quality of the product.
3

2.3 Polymerization
Under the right conditions styrene can polymerize violently. This is an exothermic
reaction; therefore, once polymerization begins it can escalate out of control.
3

Polymerization is most likely to occur in the purification and storage phases of
production. Inhibitors are necessary to prevent this. For the storage tanks 4-tert-
Coke
Coke
Butylcatechol, or 4-TBC, is used in a concentration of 15 ppm. The tank is held
below 75F and oxygen is bubbled through the tank to increase the lifetime of the
styrene product. In the distillation columns 2,4-Dinitrophenol is fed continuously.
10

These steps allow the final product to be sold at a purity of 99.93% styrene
monomer, this is equal to the industry standard.
3 Objectives
The following objectives were satisfied in the design:
1.) To design a plant with the capacity to produce styrene monomer at a rate of 2.2
billion lbs/yr with a purity at or above the industrial standard of 99.93 wt%
2.) To analyze the design to determine whether it is economically competitive at the
average market price over the past three years
3.) To develop the design with the following design norms in mind:
a. Justice and caring Design decisions were made that consider the rights
and needs of all stakeholders, even those seemingly unaffected by the
plant. If styrene products can be made available to more people at a
lower cost, people of a wider economic range might be able to benefit
more from this product.
b. Trustworthy People living around this plant need to trust that they will
be safe, even in the case of an accident. Customers need to be able to
trust the operators of the plant to have the amount of styrene promised at
the specification needed. Customers rely on knowing that the process
will not only run continuously, but also at the required purity.
c. Stewardship Caring for the earth and all that is in it was a key motivator
in designing a chemical processing plant. Making sure that the plant is
optimized to not have more adverse affects on the environment than is
necessary and also being sure that none of our starting materials go to
waste, but are used to their fullest potential. Additionally, optimized
equipment allows the plant to operate using the less energy than non-
optimized.
4.) To simulate the design using HYSYS
5.) To choose a suitable location for the plant to be built
6.) To determine the design specifications on the following pieces of process
equipment: compressors, turbines, pumps, heat exchangers, distillation columns
and reactors.
4 Process Description
The process to synthesize styrene monomer from ethane and benzene can be
simplified to four stages: alkylation, dehydrogenation, light gas separations, and
separations of aromatic products. However, starting with different raw materials
would lead to different designs.
4.1 Design Alternatives
There are two major design alternatives prevalent in industry today. The first is the
production of styrene from ethylene and benzene via an ethylbenzene intermediate.
The second is the co-production of styrene and propylene oxide from ethylene,
benzene and propylene.
4.1.1 Styrene from Ethylene and Benzene
The production of styrene from ethylene and benzene is the most common industrial
process to produce styrene. A basic Friedl-Crafts Alkylation occurs between
ethylene and benzene forming ethylbenzene. The ethylbenzene is then
dehydrogenated to form styrene.
11
These are the same as reactions 1a and 2a,
respectively. Therefore, the impurities, catalysts, and separations of aromatic
products are the same as with the designed process.
4.1.2 Co-Production of Styrene and Propylene Oxide
Styrene is produced via the oxidation of ethylbenzene (formed from ethylene and
benzene) to ethylbenzene hydroperoxide. The ethylbenzene is epoxidized with
propylene, forming propylene oxide and -phenylethanol, the later of which is
dehydrated to form styrene. The amount of styrene produced is very dependant on
the market for propylene oxide because this process is a co-production. This process
also requires very complex and costly separations due to the aldehydes that form and
hinder the polymerization of styrene, a major concern for the customer.
3

4.2 Area 100 Alkylation
The distillation reactor system requires four distillation reactors (R-100) run in
parallel, one distillation column (T-100), and four packed bed reactors (R-101) run in
parallel. The process begins with benzene and ethylene reacting to form
ethylbenzene, the precursor to styrene.
4.2.1 Equipment Design
A Friedl-Crafts alkylation occurs in a distillation reactor system. Benzene and
ethylene (recycled from the ethylene and ethane separations process) enter a
distillation reactor. The distillation reactor contains twenty-five trays, but is packed
with catalyst in the upper 30 vol% of the reactor.
4
It is 6.5m tall and has a 1.9m
diameter. Two streams enter the reactor system; one is rich in benzene and the other
is rich in ethane with 9.01 mol% ethylene. The ethane exits as the distillate of R-
100, thus removing a distillation column from the Area-300 design. The inlet stream
with ethylene can operate at concentrations up to 95% ethane, with the remainder
ethylene. The boiling point of ethylbenzene is greater than ethane or benzene, so
once the ethylbenzene is formed it falls down the reactor as the bottoms product.

This reactor design has several advantages over the more industrially common
packed bed reactor:
4

1.) High conversion of ethylene is controlled by having a 10:1 ratio of benzene to
ethylene and sufficiently large height of packed catalyst. This minimization of
unreacted ethylene reduces separation and recovery problems.
2.) The benzene that comes off the reactor as the distillate is recycled back to the
reactor feed. A purge is added so that very light gasses do not accumulate. Only
the benzene that has reacted leaves the distillation reactor.
3.) The continued removal of the alkylated and polyakylated products forces the
chemistry in Reaction 1a to favor the products. This also minimizes both the
polysubstitution and decomposition of the product.
4.) Because the compounds in the distillation reactor are boiling, the temperature at
which the reaction takes place is controlled by the boiling point of the mixture.
This has the further advantage that as the exothermic alkylation takes place the
reaction enthalpy increases the boil-up.
5.) The rate of reaction and distribution can be well controlled by regulating the
system pressure. Thus, upon piloting this process, the distillation reactor
efficiency can be increased significantly.
6.) Two stages are condensed into one; the first stage would consist of the reaction
of benzene and ethylene to ethylbenzene. The second would be the separation of
benzene from ethylbenzene. These two processes occur in one distillation
reactor.
The bottom products from the distillation reactor are then sent to a distillation
column, where the polyalkylated benzenes (mostly di- and tri- ethylbenzene) are
separated from ethylbenzene. This design achieves a purity of 99.78 mol%
ethylbenzene in the distillate. The bottoms product is entirely byproducts. The
polyalkylated benzenes, along with the heavier impurities, are sent to a
transalkylation reactor where reaction 1b occurs. The transalkylation unit is a
packed bed reactor. In the presence of more benzene, the formation of ethylbenzene
from the polyalkylated benzenes is favored.
3
The unconverted polyalkylbenzenes
are then recycled to distillation column T-100. The 99.78 mol% pure ethylbenzene
is sent on to the dehydrogenation.
4.2.2 Catalyst Design
There are two catalysts used in Area-100. EBZ-500S is available from UOP and is
used in the distillation reactor. Its a zeolite catalyst in the solid -phase. It has a
spherical shape with a nominal diameter of 2.2mm and is absent of precious metals.
Unwanted side-reactions are minimized and it more resistant to poisons like water,
oxygenates, olefins, chlorides and sulfur. EBZ-500S has a life time of five years
without regeneration and can be regenerated up to three times, thus allowing the
catalyst to be used for 20 years before replacement.
5
It is available from UOP for
approximately $105 per pound.
12
When used in conjunction with EBZ-100 in the
transalkyation, a purity of 99.97% ethylbenzene can be achieved. EBZ-100 is
another catalyst also available through UOP. It is specifically designed to operate in
the transalkylation. It is also a solid zeolite catalyst with no precious metals and has
a nominal diameter of 1.6mm with an extrudated shape. Its life time is five years
without regeneration and it can be regenerated three times, and needs to be replaced
every 20 years.
13
Its cost is $40 per pound.
12
Together these solid catalysts will
provide the desired conversion for the distillation reaction system.
4.3 Area 200 Dehydrogenation
The fresh ethane feed and the ethylbenzene formed in Area-100 enter the
dehydrogenation . Four reaction vessels designed to the specifications of R-200 and
R-201 are used in parallel, allowing for temporary shutdown of one reactor. Here
Reactions 2a and 2b form the main product, styrene, along with ethylene. Side
reactions occur to form toluene, benzene, and coke.
4.3.1 Equipment Design
The fluidized catalyst cracking reactor (FCC) has two reaction vessels, RV-200 and
R-201. Ethane and ethylbenzene enter R-200 and form the dehydrogenated products
ethylene and styrene respectively. At the inlet of R-200 the ethane to ethylbenzene
volumetric feed ratio is 4.08:1. At this feed ratio, the product of conversion and
selectivity for Reaction 2a is 48% and for Reaction 2b is 9.7%.
7
R-200 uses the
Optimix LSi FCC feed distribution system available through UOP LLC. The
ethane and ethylbenzene carry the solid catalyst to the top of the reactor, where it
exits through special disengaging arms which generate a centrifugal flow pattern.
14,15

This is designed to disperse the catalyst uniformly in the riser of the reaction vessel.
The catalyst remains fluidized by the reagent mixture in the gaseous phase. The
dynamics of the reaction vessel cause the catalyst to move downward (due to
gravity) and components in the gaseous phase to move counter-current to the
catalyst. This causes thorough mixing between the catalyst and reaction
components. Ethane, ethylene, ethylbenzene, styrene, toluene, and benzene are the
major compounds leaving the FCC chamber, along with the dehydrogenated form of
the Area-100 byproducts. A solid side product, coke, is produced via Reactions 2c
and 2d, and deposits onto the catalyst.
3
The gaseous products leave the reactor
through a solid filtering technique, known as cyclones. The cyclones extend towards
the bottom of the riser, but stop before the catalytic stripping part of R-200. This
design is common in VSS reactor systems available through UOP LLC. It contains
the hydrocarbons to the riser of the reactor and pre-strips the catalyst.
15
The catalyst
falls further to an AF spent catalyst stripper, also available through UOP LLC. In
the catalyst stripper, absorbed hydrocarbons leave the catalyst particles. The catalyst
falls to the bottom of the stripping trays and is sent to regenerator R-201.
16

In the regenerator the coke deposited on the catalyst is burned off via air at 560C,
producing carbon-dioxide. Hydrogen, recycled from Area-400, also enters R-201
and is combusted to produce water. By this process, the catalyst is heated to 680C
and transported back to R-200. The high temperature of the catalyst provides the
heat of reaction for Reaction 2a and 2b to occur. There are several reasons to use a
reactor-regenerator system:
7

1.) The catalyst is continually regenerated. By continually removing coke the
catalyst will not degrade over time. This means the operating parameters and
catalyst performance will be constant for the lifetime of the plant.
2.) The heat for Reactions 2a and 2b are provided by the catalyst, thus super-heating
ovens are not needed.
3.) The re-mixing of the fluidized bed prevents hot spots from forming, which would
lower selectivity.
4.) The hydrogen can be recycled to R-201, where it is burned.
5.) The process can be made continuous without changing the operating parameters
of the plant over its lifetime.
6.) R-200 and R-201 are physically separate. This disallows mixing between the
hydrocarbons and any oxygen, an inherent process danger.
7.) Less inert gas needs to be used in the feeding to the reactor, thus higher
concentrations of the reactants can be used, which lead to higher reaction
selectivites.
4.3.2 Catalyst Design
This process is very catalyst-specific. Therefore, the design and development of the
catalyst is crucial. The catalyst in Area-200 is comprised of less than 10 wt% Ga
2
O
3
,
20 wt% Fe
2
O
3
, 100 ppm platinum, and the remainder alumina. The catalyst is
synthesized in a four-step process. The promoters are added to the carrier via an
aliquot. The sample dried at 150C and calcinated at 900C. The iron oxide and
remaining promoters are added to the carrier. The catalyst is dried and calcinated
again, as described previously.
7
In order to determine the amount of catalyst needed
for a given feed composition, data from Figure 1 was taken from US patents
#6,031,143:
Weight of Catalyst vs. Ethane to EB Volumetric Ratio
y = 498.18x
-0.6678
R
2
= 0.9967
y = 17.28x
0.5396
R
2
= 0.9996
0
50
100
150
200
250
300
0 2 4 6 8 10 12
Ethane/EB vol
g
/
h
/
k
g
c
a
t
Styrene Ethane

Figure 1: Weight of Catalyst vs. Ethane and Ethylbenzene Volumetric Ratio

The catalyst for the selective combustion of hydrogen is available through UOP and
is OC-5. It is a solid sphere with a nominal diameter of 3.8mm and a density of
750 kg/m
3
.
17
OC-5 uses platinum as a promoter and is available at $115 per
pound.
12

4.4 Area 300 Separations of Aromatic Products
The separations system is set up to recover styrene at a purity of 99.93%, toluene at a
purity of 99.75%, benzene at a purity of 99.85%, and ethylbenzene at a purity of
98%. This system uses seven distillation columns of which three are for the
purification of styrene. The inhibitor 2,4-dinitrophenol is used in this system to
prevent the polymerization of styrene. The components that enter Area-300 can be
simplified into six categories: Light gases, C
6
non-aromatics (modeled as n-hexane),
benzene, toluene, ethylbenzene, styrene, and heavy aromatics.
4.4.1 Separations Train and Column Design
In column T-300, light gases such as ethane and ethylene are vented to the light
gases area. Toluene and benzene are separated from ethylbenzene and styrene. To
ensure minimal styrene polymerization product the temperatures should stay low. T-
300 is a packed column which uses Flexipac HC structured packing, available
through Koch-Glitsch. The advantage to using structured packing is that there is a
small pressure drop across each stage of approximately 0.05 psi. This minimizes the
temperature difference across the column and therefore the temperature necessary in
the reboiler, which is crucial in preventing polymerization of the styrene product.
The column operates at vacuum conditions with a pressure of 26.7 kPa. It contains
66 stages, with the feed entering in the 50
th
stage. The diameter is 2.04m and its
height is 40.23m. The reflux ratio is optimized at 12:1. The distillate product is rich
in toluene (49.6 mol%) and benzene (49.1 mol%), with some n-hexane (1.2 mol%)
and the remainder ethylbenzene (0.1 mol%). These products are sent to column T-
301.

In T-301, a column of 23 trays, toluene is purified and leaves as the bottoms product.
It has a purity of 99.8% toluene, which is then to spot sold as high-grade toluene. T-
301 is a sieve-tray column with a diameter of 2.04m (6.7ft) and a height of 14.02m
(46ft). Sieve trays are used because polymerization in not a concern, and is less
expensive. The operating pressure is 26.7 kPa. The reflux ratio is optimized at 3.4:1
and the optimum feed inlet is tray ten. The distillate is mainly benzene, with some
non-aromatic impurities. It is then sent to column T-302 for further separation.

Column T-302 separates benzene from non-aromatic C
6
hydrocarbons in 40 sieve
trays. This process is economically viable because the recovered benzene can be
recycled to Area-100. Like column T-302, sieve trays are used because costs can be
reduced without sacrificing product purity. The optimum feed inlet is in tray 28, and
optimum reflux ratio is 15:1. The diameter is 2.1m (6.9ft) with a height of 14.63m
(48ft). The operating pressure is 26.7 kPa. The benzene is purified to 99.85 mol%.

The bottoms product from column T-300 contains ethylbenzene (49.4 mol%),
styrene (50.4 mol%), the toluene (0.17 mol%) and the remainder heavy aromatic
byproducts. These are sent to column T-303, where the ethylbenzene is separated off
the top to be recycled to Area-200. Like T-300, this column uses Flexipac HC to
reduce pressure drop across the column. T-303 is 72 stages, with an optimum feed
inlet at stage 48 and optimum reflux ratio of 10:1. To further reduce operating
temperatures, and thus the possibility of polymerization, the pressure is decreased to
7.99 kPa. The diameter of T-303 is 5.33m and the height is 43.89m.

The remainder of the styrene product is then sent to T-304, where it is then purified.
Column T-304 incorporates the same packing as previously mentioned above the
feed inlet, and trays in the stages below the feed inlet. The advantage to designing a
hybrid column like this is due to some of the styrene monomer beginning to
polymerize. If any styrene polymerizes enough to form a solid within the column
then it will deposit onto the tray. Occasionally the column will need to be opened
and the trays cleaned to remove any solid polymer residue. This is easy to do with a
sieve tray and very difficult with packing. Since the highest temperatures are in the
reboiler, the polymers are most likely to form at the bottom of the column, on the
sieve trays. T-304 operates at a lower pressure (5.33 kPa) than column T-303. It has
a height of 27.4m and a diameter of 5.2m. The optimum reflux ratio is 0.75:1. The
total number of trays is 45 and the feed enters on the 24
th
tray. The bottoms product
is then further purified in T-305. The distillate is purified styrene and is sent to
storage or to the customer.

Column T-305 has a similar design to T-304. It is another hybrid column with
structured packing from stages one to fifteen and sieve trays from sixteen to the last
tray, thirty. It operates at 5.33 kPa, with a height of 18.3m and a diameter of 3.3m
(10.9ft). The optimum reflux ratio is 1.29:1. The bottoms product is sent to column
T-306. The distillate joins with the distillate from T-304 and goes to storage and for
sale.

The final column in Area-300 is T-306. It has the same dimensions as T-305 and
same tray design. The only difference is that it operates with a reflux ratio of 15:1.
The distillate product in columns T-304, T-305 and T-306 are mixed to produce the
final styrene product available at a purity of 99.93 wt% styrene. The bottom
products of T-306 are the heavy side-products. They are mixed with the heavy
byproducts from the alkylation and sent to be incinerated.
4.4.2 Separations Inhibitors
Without inhibitors the distillation design in Area-300 would not work.
Polymerization would occur often, causing the columns to need to be shut down
frequently for cleaning. Therefore, the inhibitors that are used, and where they enter
the process, are important. There are two different types of inhibitors: retarders
(which slow polymerization) and true inhibitors (which stop polymerization in the
free radical stage).

The inhibitor which retards the polymerization process is 2,4-dinitrophenol. It is
added in the liquid stream coming from the condenser on column T-303, the first
column where the styrene product is purified. It will then fall through column T-
303, where the concentration of styrene increases as the inhibitor moves down the
column. It is carried through T-306 and removed before the styrene is sent to storage
tanks.

After removal of the 2,4-dinitrophenol, but before storage, the inhibitor 4-TBC is
mixed into the styrene product stream. It stops polymerization by interacting with
the free radicals formed in the initiation step of the polymerization mechanism. In
the storage tanks, oxygen is bubbled through the tank to activate the 4-TBC. The
styrene product is sent to customers with the 4-TBC present. Customers remove it
by adsorption when polymerization is desired.
4.5 Area 400 Light Gas Separation
The products from Area-200 are cooled to -50C and then separated in V-202 so that
the vapor products are rich in ethane, ethylene, nitrogen, and hydrogen and the liquid
products contain the aromatic products from the dehydrogenation. The vapor
products are then sent to Area-400, the light gas separations. Here the ethane and
ethylene are separated from the hydrogen and nitrogen via a series of compression,
cooling, expanding and two-phase separations. The necessary equipment includes
33 compressors in eleven compression stages, 30 heat exchangers, ten turbines, and
ten two-phase separators. Under ideal circumstances, ten throttling valves would be
used instead of turbines that operate at 85% efficiency. However, HYSYS could not
correctly model an isoentropic expansion for this case. If throttling valves were used
a cost reduction could be seen in both the equipment savings and in the compressor
duty. Because the turbine is not 100% efficient, some of the enthalpy of expanding
the gas goes to entropy, which must be made up by the compressors. The two-phase
separators operate at a range of temperatures from -68.5C in the first stage to
-168.2C in the last stage. The temperatures after compression get as high as 42C.
Three streams leave Area-400. The first is the bottoms product of the first two phase
separator and consists of mostly styrene, ethylbenzene, and other aromatics. The
second is the distillate recovered after ten two-phase separators. At -159.4C, it is
comprised of 64.9 mol% nitrogen, 34.9% hydrogen, and the remainder ethane and
ethylene. This stream is sent to Area-200 and is burned in R-201 to provide heat for
the reaction. The third stream is the mixture of the bottoms of each two-phase
separator, and is rich in ethane and ethylene at 90.0 mol% and 9.98 mol%
respectively. This stream is fed to Area-100 and supplies the ethylene feed for
Reaction 1a. Area-400 is the most expensive area in the process.
4.6 Heat Exchanger Design
Sixty-six heat exchangers have been designed in the process. The fundamental
design equation is:
17

lm
T UA q = Equation 1
where q is the total heat transferred, U the overall heat transfer coefficient, T
lm
is
the log-mean temperature difference, and A is the area used for exchanger design.
The overall heat transfer coefficient is estimated from design tables provided by
Peters, Timmerhaus and West.
18
Water is the coolant for streams needing to be
cooled down to 15C. It is used in the condensers in Area-300 and on exchanger E-
202.1. The coolant, R-22, is available to -60C and is primarily used in Area-400.
19

The reboilers in Area-300 use exhaust steam available at 150 kPa and 109.95C for
heating the product streams. However, one exchanger uses saturated steam at 3550
kPa and 243.38C. Area-300 accounts for a total of sixteen exchangers. Area-400
uses thirty exchangers for interstage cooling after compression. Eleven exchangers
are used in Area-100 and ten exchangers are used in Area-200. The pressure drop
across the tube and shell side of each exchanger can be calculated. An example
calculation can be seen in Appendix E.1. The pressure drops were also increased to
account for losses due to piping and to ensure that estimates are on the conservative
side. The specifications on each exchanger can be seen in Appendix A.2. The cost
is a function of exchanger area and duty of the coolant or steam.
4.7 Pump, Compressor and Turbine Design
There are fifteen places in the plant design where vapor compression is necessary.
At each point the compressor arrangement is optimized. Forty-one compressors
operating at 75% efficiency are used in the process. The optimum arrangement
requires anywhere from one to six compressors with interstage cooling. Area-400
requires thirty-two of these compressors in order to separate ethane and ethylene
from nitrogen and hydrogen. The optimum arrangement was determined by
specifying that the duty on each compressor in one chain is equal, and a cost analysis
done for each case. This required over eighty various arrangements to be evaluated
and the optimum fifteen to be taken from this. The cost of each compressor was
determined from the material of construction, size and duty required. The cost of
each compression chain was the sum of the compressor and heat exchanger costs
annualized over twenty years.

There are ten turbines in the process; all of which are used in Area-400. Each
turbine is 85% efficient and used to cool the vapor into the two phase region. The
cost on each turbine is determined from the material of construction, size and duty.

There are four pumps needed in the process. They are on the benzene feed to Area-
100, benzene recycle from Area-400 to Area-100, and the toluene and styrene
products from Area 300. The cost of each pump is determined from its material of
construction, capacity, duty and pressure. Calculations and specifications for each
compressor, turbine and pump can be seen in Appendices A.1, A.6 and A.3,
respectively.
4.8 Materials of Construction
Carbon or stainless steel is used in all areas of the plant. Carbon steel is generally
less expensive than stainless steel, but has two problems. First, it degrades at
temperatures above 455C. Carbon will segregate from the piping, putting graphite-
like deposits into the process.
19
Therefore, in all areas operating above 455C
stainless steel is used. This is most prominent in Area 200. Reactors T-200 and T-
201 reach temperatures above 600C. The product stream is cooled below 400C
after exchanger E-200. However, the product stream contains hydrogen gas. The
second problem with carbon steel is that hydrogen gas can imbed itself within the
material, degrading the steel over time.
18
Therefore, carbon steel cannot be used
again until Area-300 and cannot be used at all in Area-400. The materials of
construction greatly effect equipment cost. Therefore, whenever possible carbon
steel is used instead of stainless steel.
5 Environmental, Health and Safety Issues
Christian engineers are called not only to design for profit, but to design in a manner
that glorifies Gods creation and respects His people. Therefore, the design of this
plant includes taking consideration of environmental issues, as well as concerns for
the well-being of all people that might be impacted by the plant or its products. This
concern for the stakeholders in the plant guides this design.
5.1 Environmental Concerns
One of the design objectives is to show stewardship and therefore minimize the
impact on the environment. The importance of this objective cannot be overstated.
The environment consists of the land, water, air, animals and people near the plant.
One major byproduct is carbon dioxide. This is created from the incineration of
gaseous hydrocarbon side products and the burning of coke on the catalyst. Streams
306 and 311 are to be combusted to carbon dioxide and water. Purge stream 227
also contains carbon dioxide. All products are to be sent though scrubbers to reduce
the carbon monoxide content from side combustion reactions and bring the limits
within the National Ambient Air Quality standards of 9ppm per 8 hour non-
overlapping average.
20
Unfortunately, the modeling of the incineration process and
estimations of the side combustion reactions are beyond the scope of the design. As
of 2004, the average American produced 5.76 metric tons of carbon dioxide per
year.
21
The designed process produces the equivalent amount of 5750 Americans in
one production year. This is a weakness of the design, and would need to be reduced
before implementation.

The other byproducts consist of heavy hydrocarbons. These are incinerated when
possible and treated when they cannot be incinerated. The modeling of this process,
and the reactions that govern it, is also beyond the scope of the design. Water
generated from the combustion of hydrogen in T-202 is sent for treatment as well.

The significant benefit to the process is that the dehydrogenation reactions (2a and
2b) occur simultaneously. Thus the designs for ethane to ethylene and ethylbenzene
to styrene plants are incorporated into one design. This is evidenced by the need for
two separations process, Area-300 and Area-400. A possible pollution reduction can
be accomplished by incorporating two plants into one. An in depth analysis of this
hypothesis is beyond the scope of the design.
5.2 Chemical Hazards
Caution should be taken when dealing with several compounds in the process.
Styrene monomer should not have contact with skin. If it does, the skin should be
washed with water for at least fifteen minutes. Styrene is extremely flammable and
can travel a considerable distance to an ignition source and should be put out using a
dry chemical, alcohol foam or carbon dioxide. Pure styrene has a penetrating odor.
The flammability limits lie from 1.1 wt% to 6.1 wt%. Styrene waste should be
mixed with a more flammable solvent and then be atomized into an incinerator.
22

The precursor to styrene, ethylbenzene, is also dangerous. It should never be inhaled
and CPR may be needed after doing so. It is labeled as a severe fire hazard and the
same method of fire fighting used for styrene should be applied to ethylbenzene.
23

Benzene is an eye irritant and causes nausea, unconsciousness, and a change in blood
composition when breathed in. It is also a fire hazard, and should be put out with the
same method as styrene and ethylbenzene. The flammability limits are from 1.3
vol% to 7.9 vol%. A self contained breathing apparatus should always be used when
around benzene that could enter the surrounding air.
24
Ethane is non-toxic but can
cause asphyxiation. It is also a fire hazard. If a cylinder is exposed to fire it may
rupture. The flammability limits are from 3.0 vol% to 12.5 vol%.
25
Ethylene can
cause dizziness, asphyxiation, drowsiness, unconsciousness and muscular weakness
from overexposure. It is flammable, with limits from 3.1 vol% to 32.0 vol%. Fires
for both ethane and ethylene are best treated by removing or shutting off the
source.
26

5.3 Safety Hazards
Safety is a primary concern in all areas of the process. There are three major
variables that affect equipment safety. They are the operating pressures,
temperatures, and the chemicals present. Choosing the appropriate materials of
construction (see sect 4.8) reduces the dangers associated with temperature and
certain chemicals. For example, carbon steel cannot be used above 455C or with
hydrogen gas, thus stainless steel is the appropriate material in streams which carbon
steel cannot be used. For equipment operating at high pressures, the thickness of
equipment must be increased. This is taken into account as a pressure factor used
when costing equipment. The flammability of each stream is also taken into
consideration. The only streams with oxygen present enter regenerator R-201. The
oxygen is consumed in the reaction. All other streams operate well above the upper
flammability limits. Using pressure, temperature, level, and flow controllers the
streams can be kept within the designated safety ranges.
6 Control Design
Whatever can be controlled in the process should be controlled.
27
Controls are vital
to the safety of a process and are, therefore, incorporated in the design to converge
the real-world variables to the design variables. They are designed to check for
unsteady states, minimize the occurrence of unsteady states, and then correct the
problem. As such, the time lag between the occurrence of a problem and the
correction needs to be minimized. This is done by placing controls where they can
have the fastest impact.
6.1 Control Design on Area 100
The fresh benzene feed is to be controlled via a flow controller, which measures the
flow rate of incoming benzene. This controller disallows backflow to benzene
storage tanks and adjust the feed so that the benzene to ethylene ratio is 10:1 in R-
100. A temperature controller is used to verify this specification and is on the
reboiler, so that it will have a direct impact on space time and reaction temperature
inside R-100. Since there are actually four R-100 reactors in parallel, the feed
controller needs to be on each incoming stream. This would allow for temporary
shutdown or production rate decrease. However, the process is designed to operate
under constant production conditions and not vary with market demand or equipment
failure. R-100 has a flow controller on the condenser, which affects the ethane going
to Area-200. Column T-100 has two level controls; one on the reboiler and
condenser each. The bottoms of T-100 are sent to R-101, but with a flow control on
the purge stream. Like the benzene inlet control on R-100, this control varies the
polyalkylated benzene feed to keep its ratio with benzene constant.
The ethylbenzene and ethane from Area-100 is mixed with ethylbenzene from Area-
300 and fresh ethane feed. There is a feed controller on the ethane feed, controlled
based on the product from Area-100. The mixed stream is sent though exchanger E-
200, where a temperature control is used to stabilize temperature fluctuations. The
ethylbenzene is sent though a series of compressions and then mixed with inert gas.
This stream is sent though E-201, where the temperature entering the reaction needs
to be consistent and is controlled by a temperature controller. The product from T-
200 is sent through a flow control, which is modified based on the temperature after
E-202. After filtration, another temperature is used for exchanger E-204, so that the
temperature into the two-phase separator, V-200, is consistent and will cause the
aromatic products to be sent to Area-300 and the light gases to Area-400. Because
this controller determines the split in V-200 it will affect the entire process.

The air feed to Area-200 has a flow controller across a gate valve and then a pressure
controller on compressor K-201. This stream is heated by the product from T-201,
thus a flow controlled bypass is used to control the temperature of this stream. Its
temperature is vital because it causes the combustion in T-201 to occur, which
provides the energy for the reactions in T-200. The product stream from T-201 is
also heat exchanged with the hydrogen and nitrogen inlet from Area-400. A flow
controlled bypass is again used to control the temperature of both streams. The
product stream is filtered and another temperature controller used across the heat
exchanger before V-201. After a series of compression, where a pressure controller
is used, E-202 has a temperature control. When separated in V-200, the gaseous
nitrogen and carbon dioxide are sent across a flow control. This control varies how
much is purged and how much is sent to R-200 to fluidize the reactor bed.
There are three parameters that need to be controlled in Area-300. They are: the exit
composition of each column, the column pressure, and the reflux ratio on each
condenser. The first controller is a flow controller used directly before T-300. The
column then has six controllers. Because this column operates under vacuum
pressure, the pressure control is crucial. Depending on the column pressure, the
temperature, reflux and flows will all change. Therefore, it is essential that the
pressure meets the specs by which the column was designed. The pressure control
can open a gate valve used to vent off gases in case the pressure is too high. The
temperature control is on the column. The equilibrium within the column dictates
that a specific composition resides at a specific temperature. Thus a flow control is
connected to the reboiler exhaust steam. A level control varies what leaves T-300
through the bottoms and another level control is used on the condenser. On the
condenser, the level control operates a gate valve on the product stream. Its function
is to set the reflux ratio, which should be converged to the designed optimum reflux
ratio. Lastly, a flow controller controls how much reflux is sent back to T-300.
Since this is the first column in the distillation chain, it may be tempting to put two
temperature controllers on the column, each one to specify the composition on either
end. However, studies have shown that this creates many problems because the two
controllers are not mutually exclusive. One controller can interfere with the other
based on how much it tries to control the exchanger duty. Using only one
temperature controller is easier and still does a good job.

Columns T-301, T-302, and T-303 are designed in a similar manner, with six
controllers per column used to control the composition, pressure and reflux ratio.
For each of these columns, the reflux ratio is greater than one, and so the gate valve
for the level control on the condenser is positioned on the product stream. When the
reflux ratio is less than one, then the level control is on the condenser coolant, as
with T-304 and T-305. The flow control is on the product stream, and another flow
control manages the reboiler steam. A level control operates a gate valve on the
bottoms product. T-306 has a reflux ratio above 1, so there is a level control on the
distillate, and flow control on the reflux. However, the bottoms are designed with
the level control on the product stream, and the flow control on the reboiler steam.
The mixed styrene product stream is then sent to storage. There is a flow control on
this final stream.
Even though Area-400 has eighty two pieces of equipment, the control design is
simple. Every compressor has a pressure control. Every heat exchanger has a
temperature control and a flow control on the coolant. Every turbine has a pressure
control as well. Therefore, there are 102 controls used in Area-400 total.
7 Economic Analysis
Capital, utility and raw material costs along with revenue from the products
determine the profitability of the design. The purchase and installation of
equipment, land and piping affect the capital cost. Of these, the largest contributor to
the capital cost is from the equipment. This is priced according the cost spreadsheets
available from Peters, Timmerhaus and West. Direct costs, indirect costs, and
working capital affect the total capital investment. A few direct costs are the
purchased equipment, delivery, installation, piping and instrumentation costs.
Indirect costs are things like construction and legal expenses, engineering and
supervision, contractor fees, and contingency costs. Working capital is the cash on
hand needed to start the plant. The total capital investment is 2,508.7 million dollars.
Raw material costs are from ethane, benzene, air, OC-5, EBZ-100, EBZ-500S, TBC,
and DNP. The annual cost of all raw materials is 731.5 million dollars. Electricity,
refrigeration, steam, water treatment, and cooling water usage determine utility costs.
The total is 197.8 million dollars per year. The revenue generated from the products
styrene and toluene is 1,976.2 million dollars per year. The selling price for styrene
is $0.99 per pound. The variable costs consist of raw material costs, utilities and
general expenses; projected at 1,084 million dollars per year. The fixed costs include
fixed charges, plant overhead and general expenses; and are 297.7 million dollars per
year.
18

The price for the styrene is chosen by varying the Investors Rate of Return (IRR). If
the IRR is set to 15.0%, the price of styrene is $0.99 per pound as shown in Figure 1:
IRR Analysis - Product Price Fluctuation
-5.0%
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
30.0%
35.0%
$0.70 $0.80 $0.90 $1.00 $1.10 $1.20 $1.30 $1.40
Styrene Monomer Product Price ($/lb)
I
R
R

Figure 2: IRR Analysis Product Price Fluctuation

15.0% IRR is a common value and a good starting point.
28
The Net Present Value
for this IRR is 1.99 million dollars, which is basically zero when compared to the
high capital costs. Equation 2 can be used to solve for the IRR:

=
+
=
n
i
i
i
IRR
CF
0
) 1 (
0 (Equation 2)

The return on investment (ROI) stabilizes after the sixth production year, where it is
15.4% for the lifetime of the plant.
8 Uncertainties and Assumptions
Most of the process specifications used in the HYSYS simulation came directly from
the patents. Generally, having some data is better than no data. This is true of the
data provided in the patents as well. However, the patents often provide one value
for one experiment. Without having multiple experiments run for each point, one
must trust the validity of that data point. In designing a pilot plant, this may not be a
big deal. When designing a plant to accumulate 14% of an already competitive
market more data would be better.

In HYSYS, the design was simulated using the General NRTL fluid package. The
NRTL is a local-composition thermodynamic model, and therefore, analyzes the
system according to its molecular interactions.
9 Future Work
Broadening the scope of the design would lead to the possibility to do a lot of further
work. Some of the most important work could be done to minimize pollutants. The
current design produces 33,098,000 kg/hr of carbon dioxide. This amount needs to
be reduced. Public opinion of processes that produce greenhouse gases is
continually becoming more negative. In order to be good stewards, the amount of
pollutants placed in the atmosphere must be reduced. To do this analysis, a
simulation of the combustion and side reactions should be done in HYSYS. A way
to model the formation of carbon monoxide would make the simulation more
realistic. This leads to stack scrubbing costs having an impact on the economic
analysis because the costs associated with the treatment of this gas can rise quickly.
Too much carbon monoxide production (or inadequate smokestack design) would
lead to fines from the EPA.

The fluidized catalyst cracking reactor could be designed with greater detail. If a
kinetic model could be developed and then used to design the various parameters of
the reactor, then the estimates on the reactor size could be improved. This would
help in pricing the reactor system. The reactor price is currently an educated
estimate. A more accurate price would improve the economic analysis as a whole.
FCC simulation software is also available. This would help because interpolated
values in the patents do not account for catalyst degradation. In fact, the values in
the patents are for a very specific system, using a specific catalyst and reactor set-up.
Any method for further modeling the FCC system that allows these parameters to
change would only improve the simulation.

The computer simulation software, HYSYS, can simulate processes which involve
solids. However, the HYSYS software used for this design does not have this
license available. A solid modeling license would allow the catalyst regeneration
step to be simulated, thus making the simulation more realistic. Filters that remove
solid catalyst particles from the regeneration product stream could also be simulated.
A better estimate of the pressure drop across a filter could be determined. Currently,
a valve simulates the pressure drop across a filter in HYSYS.

The HYSYS simulation also has another problem: it cannot model throttling valves.
Therefore, the designed process used expanders that were 85% efficient. Since this
caused a loss of energy and increased equipment costs, the turbines are far less
favorable than throttling valves.

There are sixty-six heat exchangers used in the process. The overall heat transfer
coefficients for each exchanger could be improved. Currently, all heat transfer
values are estimated using Peters, Timmerhaus and West, which gives a range of 250
to 600 W/m
2
K for medium organics cooled with water, and a range of 250 to 500
W/m
2
K for medium organics heated with steam.
18
These temperature ranges can
vary the exchanger area significantly. Because the components are generalized and
the heat transfer coefficient given a broad range of possible values, it is likely that
the estimated heat transfer coefficients used for doing heat transfer area design are
wrong. A detailed analysis of all sixty-six exchangers would be ideal.
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(12) Cooper, Geoff. "Catalyst Costs for a School Project." E-mail to the author. 1 May
2006
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th
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Appendix Table of Contents

Appendix A: Equipment Spec. Sheets
A.1 Compressor Specifications
A.2 Heat Exchanger Specifications
A.3 Pump Specifications
A.4 Tank Specifications
A.5 Two Phase Separator Specifications
A.6 Turbine Specifications
A.7 Distillation Specifications

Appendix B: PFD / PID / Layout
B.1 PFD: Alkylation Unit Area 100
B.2 PFD: Dehydrogenation Unit Area 200
B.3 PFD: Separations Unit Area 300a
B.4 PFD: Separations Unit Area 300b
B.5 PFD: Light Gas Separations Area 400
B.6 PFD: Compressor Chains
B.7 P&ID: Alkylation Unit Area 100
B.8 P&ID: Dehydrogenation Unit Area 200
B.9 P&ID: Separations Unit Area 300a
B.10 P&ID: Separations Unit Area 300b
B.11 P&ID: Light Gas Separations Area 400
B.12 P&ID: Compressor Chains
B.13 Plant Layout
B.14 Plant Layout, Front View

Appendix C: Separations
C.1 Separations Hand Calculations
C.2 Estimates of Column Height
C.3 Fenske Equation
C.4 Dimensioning of Packed Columns
C.5 MathCad Packed Column
C.6 Summary of All Columns
C.7 Optimization Reflux Ratio

Appendix D: Compressor Optimization
D.1 Compressor Optimization Analysis
D.2 K-404 Optimization Analysis Example
D.3 Compressor Hand Calculation Example

Appendix E: Heat Exchanger Design
E.1 Example Pressure Drop Calculation
E.2 Styrene Tank Heat Exchanger Size

Appendix F: Reactor Sizing
F.1 Dehydrogenation Reactor Size

Appendix G: Economic Optimization
G.1 Investment Summary
G.2 Economic Summary
G.3 Profitability Measures
G.4 IRR Analysis Product Price Fluctuation

Appendix A: Equipment Spec. Sheets
ID Number: K-200.1 Date: 5/8/2006
Description: Dehydrogenation Feed Compressor Train Prepared By: ACJ
No. Required 1 Checked By: MJH
0.0000
0.0000
0.0001
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
Carbon Dioxide
0.8452
0.0001
0.0000
0.0003
0.0000
0.1542
0.0000
0.0000
0.0000
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Meta Diethyl Benzene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
1 Meta 3 Ethyl Benzene
Toluene
Compressor Specifications
Fluid Properties
Process Feed Flow Rate (m
3
/hr) 418300
142.4
Vapor Composition (mol%)
Inlet Temperature (C)
Outlet Temperature (C)
Inlet Pressure (kPa)
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Max Design Pressure (kPa)
Max Design Temperature (C)
Adiabatic Efficiency
Design Power (Kw)
Theoretical Power (Kw)
Centrifugal
Horizontal
Carbon Steel
461590
4000
480
75%
5872
5321
A.1: Compressor Specifications (1 of 41)
Design Capacity (m
3
/hr)
Material of Construction
Orientation
Design Specifications
Compressor Type
Outlet Pressure (kPa)
78.7
96.2
102.4
ID Number: K-200.2 Date: 5/8/2006
Design Capacity (m
3
/hr)
Orientation
Compressor Type
96.2
113.0
142.4
Centrifugal
Horizontal
Carbon Steel
348500
4000
480
75%
5872
5321
Design Power (Kw)
194.9
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 315800
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.8452
0.0001
0.0000
0.0003
0.0000
0.1542
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0001
0.0000
0.0000
ID Number: K-200.3 Date: 5/8/2006
0.0000
0.0000
0.0001
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
Carbon Dioxide
0.8452
0.0001
0.0000
0.0003
0.0000
0.1542
0.0000
0.0000
0.0000
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 241200
263.3
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Carbon Steel
266100
4000
480
75%
5872
5321
Design Capacity (m
3
/hr)
Orientation
Compressor Type
113.0
129.2
194.9
ID Number: K-201 Date: 5/8/2006
Description: Air Feed Compressor Prepared By: ACJ
Design Capacity (m
3
/hr)
Orientation
Compressor Type
25.0
59.5
101.3
Centrifugal
Horizontal
Carbon Steel
141760
4000
480
75%
1624
1471
Design Power (Kw)
135.8
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 128680
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.2100
0.7900
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
ID Number: K-202.1 Date: 5/8/2006
Description: Recycle Stream Compressor Train Prepared By: ACJ
0.0057
0.0000
0.0000
0.0000
0.0000
0.0246
0.0000
0.0000
0.0000
Carbon Dioxide
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.9697
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 163200
186.8
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Carbon Steel
180720
4000
480
75%
3388
3059
Design Capacity (m
3
/hr)
Orientation
Compressor Type
25.0
69.2
128.8
ID Number: K-202.2 Date: 5/8/2006
Description: Recycle Stream Compressor Train Prepared By: ACJ
Design Capacity (m
3
/hr)
Orientation
Compressor Type
31.1
75.2
183.8
Centrifugal
Horizontal
Carbon Steel
129160
4000
480
75%
3388
3059
Design Power (Kw)
264.9
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 116640
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.9697
0.0246
0.0000
0.0000
0.0000
0.0057
0.0000
0.0000
0.0000
0.0000
Description: Ethyl Benzene Recycle Stream Compressor Prepared By: ACJ
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0002
0.0000
Carbon Dioxide
0.0000
0.0000
0.0000
0.0041
0.0000
0.9957
0.0000
0.0000
0.0000
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 380800
105.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Carbon Steel
425190
4000
480
75%
3404
3049
Design Capacity (m
3
/hr)
Orientation
Compressor Type
61.7
137.4
8.0
Description: Light Gases Stream Compressor Train Prepared By: ACJ
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
-28.1
124.0
Centrifugal
Horizontal
Stainless Steel
315360
4000
900
75%
5050
4574
Design Power (Kw)
173.5
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 285600
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.5804
0.0000
0.0000
0.0000
0.0000
0.0000
0.1199
0.0000
0.2367
0.0000
0.0630
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
ID Number: K-401.1 Date: 5/8/2006
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0630
0.0000
0.0000
Carbon Dioxide
0.5804
0.0000
0.0000
0.0000
0.0000
0.0000
0.1199
0.0000
0.2367
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 320300
187.4
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Stainless Steel
353570
4000
900
75%
8730
7907
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-68.6
-30.1
101.3
ID Number: K-401.2 Date: 5/8/2006
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
-12.6
184.4
Centrifugal
Horizontal
Stainless Steel
212010
4000
900
75%
8730
7907
Design Power (Kw)
325.2
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 192030
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.5804
0.0000
0.0000
0.0000
0.0000
0.0000
0.1199
0.0000
0.2367
0.0000
0.0630
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
ID Number: K-401.3 Date: 5/8/2006
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0630
0.0000
0.0000
Carbon Dioxide
0.5804
0.0000
0.0000
0.0000
0.0000
0.0000
0.1199
0.0000
0.2367
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 109880
568.3
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Stainless Steel
121320
4000
900
75%
8730
7907
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
-12.6
322.2
ID Number: K-401.4 Date: 5/8/2006
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
-12.6
565.3
Centrifugal
Horizontal
Stainless Steel
69151
4000
900
75%
8730
7907
Design Power (Kw)
997.2
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 62628
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.5804
0.0000
0.0000
0.0000
0.0000
0.0000
0.1199
0.0000
0.2367
0.0000
0.0630
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
ID Number: K-401.5 Date: 5/8/2006
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0630
0.0000
0.0000
Carbon Dioxide
0.5804
0.0000
0.0000
0.0000
0.0000
0.0000
0.1199
0.0000
0.2367
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 35836
1750.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Stainless Steel
39564
4000
900
75%
8730
7907
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-47.9
-10.6
997.2
ID Number: K-401.6 Date: 5/8/2006
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-38.4
-1.6
1747.0
Centrifugal
Horizontal
Stainless Steel
23534
4000
900
75%
8730
7907
Design Power (Kw)
3003.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 21318
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.5804
0.0000
0.0000
0.0000
0.0000
0.0000
0.1199
0.0000
0.2367
0.0000
0.0630
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
ID Number: K-402.1 Date: 5/8/2006
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0650
0.0000
0.0000
Carbon Dioxide
0.5550
0.0000
0.0000
0.0000
0.0000
0.0000
0.1277
0.0000
0.2520
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 255200
229.5
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Stainless Steel
281630
4000
900
75%
9509
8614
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-99.6
-52.6
101.3
ID Number: K-402.2 Date: 5/8/2006
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-52.6
-8.8
229.5
Centrifugal
Horizontal
Stainless Steel
158030
4000
900
75%
9509
8614
Design Power (Kw)
443.6
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 143200
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.5550
0.0000
0.0000
0.0000
0.0000
0.0000
0.1277
0.0000
0.2520
0.0000
0.0650
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
ID Number: K-402.3 Date: 5/8/2006
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0650
0.0000
0.0000
Carbon Dioxide
0.5550
0.0000
0.0000
0.0000
0.0000
0.0000
0.1277
0.0000
0.2520
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 75477
845.5
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Stainless Steel
83311
4000
900
75%
9509
8614
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
-6.3
440.6
ID Number: K-402.4 Date: 5/8/2006
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
-6.3
842.5
Centrifugal
Horizontal
Stainless Steel
43568
4000
900
75%
9509
8614
Design Power (Kw)
1617.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 39467
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.5550
0.0000
0.0000
0.0000
0.0000
0.0000
0.1277
0.0000
0.2520
0.0000
0.0650
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
ID Number: K-402.5 Date: 5/8/2006
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0650
0.0000
0.0000
Carbon Dioxide
0.5550
0.0000
0.0000
0.0000
0.0000
0.0000
0.1277
0.0000
0.2520
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 21763
3003.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Stainless Steel
24020
4000
900
75%
9509
8614
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-37.0
5.8
1617.0
ID Number: K-403.1 Date: 5/8/2006
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-116.0
-26.7
101.3
Centrifugal
Horizontal
Stainless Steel
137710
4000
900
75%
8495
7671
Design Power (Kw)
396.8
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 124400
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.0173
0.0000
0.0000
0.0000
0.0000
0.0000
0.2374
0.0000
0.4684
0.0000
0.1215
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
ID Number: K-403.2 Date: 5/8/2006
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.1215
0.0000
0.0000
Carbon Dioxide
0.0173
0.0000
0.0000
0.0000
0.0000
0.0000
0.2374
0.0000
0.4684
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 45424
1088.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Stainless Steel
50302
4000
900
75%
8495
7671
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
34.6
393.8
ID Number: K-403.3 Date: 5/8/2006
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
34.6
1085.0
Centrifugal
Horizontal
Stainless Steel
18251
4000
900
75%
8495
7671
Design Power (Kw)
3000.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 16480
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.0173
0.0000
0.0000
0.0000
0.0000
0.0000
0.2374
0.0000
0.4684
0.0000
0.1215
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
ID Number: K-404.1 Date: 5/8/2006
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.1326
0.0000
0.0000
Carbon Dioxide
0.0968
0.0000
0.0000
0.0000
0.0000
0.0000
0.2591
0.0000
0.5114
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 108700
409.6
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Stainless Steel
120400
4000
900
75%
7683
6937
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-123.1
-31.8
101.3
ID Number: K-404.2 Date: 5/8/2006
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
37.1
406.6
Centrifugal
Horizontal
Stainless Steel
44629
4000
900
75%
7683
6937
Design Power (Kw)
1106.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 40301
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.0968
0.0000
0.0000
0.0000
0.0000
0.0000
0.2591
0.0000
0.5114
0.0000
0.1326
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
ID Number: K-404.3 Date: 5/8/2006
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.1326
0.0000
0.0000
Carbon Dioxide
0.0968
0.0000
0.0000
0.0000
0.0000
0.0000
0.2591
0.0000
0.5114
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 14856
3000.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Stainless Steel
16453
4000
900
75%
7683
6937
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
37.1
1103.0
ID Number: K-405.1 Date: 5/8/2006
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-132.0
-39.8
101.3
Centrifugal
Horizontal
Stainless Steel
105410
4000
900
75%
7012
6331
Design Power (Kw)
427.2
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 95210
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.0428
0.0000
0.0000
0.0000
0.0000
0.0000
0.2783
0.0000
0.5493
0.0000
0.1296
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
ID Number: K-405.2 Date: 5/8/2006
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.1296
0.0000
0.0000
Carbon Dioxide
0.0428
0.0000
0.0000
0.0000
0.0000
0.0000
0.2783
0.0000
0.5493
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 35962
1129.6
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Stainless Steel
39824
4000
900
75%
7012
6331
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
38.5
424.2
ID Number: K-405.3 Date: 5/8/2006
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
38.5
1127.0
Centrifugal
Horizontal
Stainless Steel
15000
4000
900
75%
7012
6331
Design Power (Kw)
3000.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 13541
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.0428
0.0000
0.0000
0.0000
0.0000
0.0000
0.2783
0.0000
0.5493
0.0000
0.1296
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
ID Number: K-406.1 Date: 5/8/2006
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0880
0.0000
0.0000
Carbon Dioxide
0.0280
0.0000
0.0000
0.0000
0.0000
0.0000
0.2973
0.0000
0.5867
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 86480
436.2
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Stainless Steel
95756
4000
900
75%
6508
5874
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-136.2
-43.0
101.3
ID Number: K-406.2 Date: 5/8/2006
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
40.1
433.2
Centrifugal
Horizontal
Stainless Steel
36512
4000
900
75%
6508
5874
Design Power (Kw)
1142.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 32965
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.0280
0.0000
0.0000
0.0000
0.0000
0.0000
0.2973
0.0000
0.5867
0.0000
0.0880
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
ID Number: K-406.3 Date: 5/8/2006
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0880
0.0000
0.0000
Carbon Dioxide
0.0280
0.0000
0.0000
0.0000
0.0000
0.0000
0.2973
0.0000
0.5867
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 12544
3000.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Stainless Steel
13898
4000
900
75%
6508
5874
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
40.1
1139.0
ID Number: K-407.1 Date: 5/8/2006
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-141.4
-47.9
101.3
Centrifugal
Horizontal
Stainless Steel
87432
4000
900
75%
6097
5501
Design Power (Kw)
448.1
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 78950
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.0159
0.0000
0.0000
0.0000
0.0000
0.0000
0.3133
0.0000
0.6183
0.0000
0.0525
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
ID Number: K-407.2 Date: 5/8/2006
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0525
0.0000
0.0000
Carbon Dioxide
0.0159
0.0000
0.0000
0.0000
0.0000
0.0000
0.3133
0.0000
0.6183
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 30448
1157.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Stainless Steel
33731
4000
900
75%
6097
5501
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
41.0
445.1
ID Number: K-407.3 Date: 5/8/2006
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
41.0
1154.0
Centrifugal
Horizontal
Stainless Steel
13014
4000
900
75%
6097
5501
Design Power (Kw)
3000.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 11743
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.0159
0.0000
0.0000
0.0000
0.0000
0.0000
0.3133
0.0000
0.6183
0.0000
0.0525
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
ID Number: K-408.1 Date: 5/8/2006
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0258
0.0000
0.0000
Carbon Dioxide
0.0074
0.0000
0.0000
0.0000
0.0000
0.0000
0.3252
0.0000
0.6417
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 72360
458.4
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Stainless Steel
80145
4000
900
75%
5707
5150
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-147.9
-55.9
101.3
ID Number: K-408.2 Date: 5/8/2006
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-55.9
34.3
458.4
Centrifugal
Horizontal
Stainless Steel
30712
4000
900
75%
5707
5150
Design Power (Kw)
1187.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 27739
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.0074
0.0000
0.0000
0.0000
0.0000
0.0000
0.3252
0.0000
0.6417
0.0000
0.0258
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
ID Number: K-408.3 Date: 5/8/2006
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0258
0.0000
0.0000
Carbon Dioxide
0.0074
0.0000
0.0000
0.0000
0.0000
0.0000
0.3252
0.0000
0.6417
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 11029
3000.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Stainless Steel
12223
4000
900
75%
5707
5150
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
40.0
1184.0
ID Number: K-409.1 Date: 5/8/2006
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-155.6
-66.6
101.3
Centrifugal
Horizontal
Stainless Steel
73585
4000
900
75%
5364
4840
Design Power (Kw)
470.8
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 66440
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.0026
0.0000
0.0000
0.0000
0.0000
0.0000
0.3322
0.0000
0.6555
0.0000
0.0097
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
ID Number: K-409.2 Date: 5/8/2006
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0097
0.0000
0.0000
Carbon Dioxide
0.0026
0.0000
0.0000
0.0000
0.0000
0.0000
0.3322
0.0000
0.6555
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 25128
1228.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Stainless Steel
27820
4000
900
75%
5364
4840
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-66.6
21.0
470.8
ID Number: K-409.3 Date: 5/8/2006
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-50.0
37.4
1225.0
Centrifugal
Horizontal
Stainless Steel
11570
4000
900
75%
5364
4840
Design Power (Kw)
3000.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Fluid Properties
3
/hr) 10437
Ethane
n-Hexane
Toluene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Carbon Dioxide
0.0026
0.0000
0.0000
0.0000
0.0000
0.0000
0.3322
0.0000
0.6555
0.0000
0.0097
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0031
0.0000
0.0000
Carbon Dioxide
0.0008
0.0000
0.0000
0.0000
0.0000
0.0000
0.3350
0.0000
0.6611
Cumene
n-Propyl Benzene
Alpha Metal Styrene
Benzene
Ethyl Benzene
Hydrogen
Oxygen
Ethane
n-Hexane
Toluene
Fluid Properties
3
/hr) 61520
138.0
Nitrogen
Water
Ethylene
Styrene
n-Butyl Benzene
Design Power (Kw)
Centrifugal
Horizontal
Stainless Steel
68172
4000
900
75%
730
659
Design Capacity (m
3
/hr)
Orientation
Compressor Type
-163.4
-151.1
101.3
ID Number: E-100 Date: 5/9/2006
Description:
Prepared By: ACJ
Inlet Outlet Inlet Outlet
0 366000 121640 0
366000 0 0 121640
-120 25 111 111
101 101 150 147
584 1.22 0.85 52.08
0.0000 0.0095 0.0125 0.0000
0.2517 0.0000 0.0000 0.2490
72.03 51.96 39.87 75.92
0.0000 0.0213 0.0254 0.0000
0.1840 0.0000 0.0000 0.6847
Viscosity - Liquid (cP)
Unit Construction
Fluid
Total Heat Transfer Area (m
2
)
Process Streams
Specific Heat (J/mol-K)
Thermal Conductivity - Vapor (W/m-K)
Flow Rate - Vapor (kg/hr)
Heat Flux (kJ/hr-m
2
-K)
391 4697
Thermal Conductivity - Liquid (W/m-K)
Duty (MJ/hr)
270680
A.2: Heat Exchanger Specifications (1 of 61)
Heat Exchanger Specifications
Unit Performance & Fluid Properties
Tube Side
Ethane/Ethylene Return Heater
Shell Side
Exhaust Steam
Flow Rate - Liquid (kg/hr)
Density (kg/m
3
)
Viscosity - Vapor (cP)
Temperature (C)
Pressure (kPa)
Material of Construction Carbon Steel
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
ID Number: T-100C Date: 5/9/2006
Description:
Prepared By: ACJ
124100 124100 0 46639
0 0 46639 0
148 148 15 111
136 133 150 147
4.12 4.12 1015.00 0.85
0.0083 0.0083 0.0000 0.0125
0.0000 0.0000 1.1360 0.0000
178.70 178.70 75.44 39.87
0.0199 0.0199 0.0000 0.0254
0.0000 0.0000 0.5953 0.0000
Cooling Water
Shell Side
1
Carbon Steel
Unit Construction
Process Streams Fluid
Tube Side
Column T-100 Condenser
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
) Heat Flux (kJ/hr-m
2
-K)
955 966
Tube Side
2
Duty (MJ/hr)
122700
ID Number: T-100R Date: 5/9/2006
Description:
Prepared By: ACJ
0 0 93690 0
37920 37920 0 93690
194 194 243 243
136 133 3550 3547
714 714 14.89 804
0.0000 0.0000 0.0172 0.0000
0.1863 0.1863 0.0000 0.1099
322.10 322.10 74.72 86.22
0.0000 0.0000 0.0374 0.0000
0.1052 0.1052 0.0000 0.6242
High Pressure Steam
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Column T-100 Reboiler
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
1922 1736
Tube Side
2
Duty (MJ/hr)
164800
ID Number: R-100C Date: 5/9/2006
Description:
Prepared By: ACJ
31025 31025 0 46640
0 0 46640 0
148 148 15 111
136 133 150 147
4.12 4.12 1015.00 0.85
0.0083 0.0083 0.0000 0.0125
0.0000 0.0000 1.1360 0.0000
178.70 178.70 75.44 39.87
0.0199 0.0199 0.0000 0.0254
0.0000 0.0000 0.5953 0.0000
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
239 966
Duty (MJ/hr)
30675
Tube Side
Column R-100 Condenser
Shell Side
Cooling Water
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
ID Number: R-100R Date: 5/9/2006
Description:
Prepared By: ACJ
0 0 23423 0
9480 9480 0 23423
194 194 243 243
136 133 3550 3547
714 714 14.89 804
0.0000 0.0000 0.0172 0.0000
0.1863 0.1863 0.0000 0.1099
322.10 322.10 74.72 86.22
0.0000 0.0000 0.0374 0.0000
0.1052 0.1052 0.0000 0.6242
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
480 1736
Duty (MJ/hr)
41200
Tube Side
Column R-100 Reboiler
Shell Side
High Pressure Steam
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
Description: Dehydrogenation Feed Vaporizer
Prepared By: ACJ
481500 612700 29670 0
131100 0 0 29670
62 79 111 111
105 102 150 147
1.72 1.47 0.85 52.08
0.0104 0.0107 0.0125 0.0000
0.3762 0.0000 0.0000 0.2490
75.15 73.49 39.87 75.92
0.0242 0.0246 0.0254 0.0000
0.1290 0.0000 0.0000 0.6847
Exhaust Steam
Material of Construction Stainless Steel
Shell Side
1
Carbon Steel
Unit Construction
Tube Side Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
1059 1546
Tube Side
2
Duty (MJ/hr)
66020
Description:
Prepared By: ACJ
612700 612700 738600 738600
0 0 0 0
129 420 600 388
263 260 133 130
3.29 1.91 0.63 0.81
0.0123 0.0209 0.0281 0.0230
0.0000 0.0000 0.0000 0.0000
81.87 124.20 104.30 89.24
0.0308 0.0726 0.1025 0.0738
0.0000 0.0000 0.0000 0.0000
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
3387 800
Duty (MJ/hr)
443300
Tube Side
Dehydrogenation Feed Heater/Product
Cooler
Shell Side
Process Streams
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Stainless Steel
Tube Side
Number of Passes 2
ID Number: E-202.1 Date: 5/9/2006
Description:
Prepared By: ACJ
236100 236100 0 0
0 0 64290 64290
69 31 15 50
187 184 220 217
1.83 2.02 1015 988
0.0200 0.0183 0.0000 0.0000
0.0000 0.0000 1.1360 0.5442
29.54 29.34 75.44 79.03
0.0287 0.0261 0.0000 0.0000
0.0000 0.0000 0.5953 0.6432
Cooling Water
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Nitrogen Recycle Stream Cooler
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
176 1610
Tube Side
2
Duty (MJ/hr)
9494
ID Number: E-202.2 Date: 5/9/2006
Description:
Prepared By: ACJ
236100 232400 0 148200
0 3757 148200 0
75 -50 -60 -5
265 262 220 217
2.55 0.14 1465 8.53
0.0202 0.0146 0.0000 0.0112
0.0000 0.0000 0.4134 0.0000
29.57 29.92 90.86 52.86
0.0291 0.0203 0.0000 0.0094
0.0000 0.4680 0.1273 0.0000
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
310 1609
Duty (MJ/hr)
40860
Tube Side
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
Description:
Prepared By: ACJ
739200 739200 0 0
0 0 0 0
451 451 0 0
260 257 0 0
1.67 1.67 0 0
0.0242 0.0242 0 0
0.0000 0.0000 0 0
105.00 105.00 0 0
0.0716 0.0716 0 0
0.0000 0.0000 0 0
Used For Start Up
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Dehydrogenation Startup/Control
Exchanger
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
803 0
Tube Side
2
Duty (MJ/hr)
0
Description:
Prepared By: ACJ
738600 738600 126500 126500
0 0 0 0
388 320 -50 846
130 127 262 259
0.81 0.88 3.95 0.79
0.0230 0.0221 0.0146 0.0523
0.0000 0.0000 0.0000 0.0000
89.24 83.14 28.74 33.09
0.0738 0.0645 0.0204 0.0713
0.0000 0.0000 0.0000 0.0000
Process Streams
Shell Side
1
Stainless Steel
Unit Construction
Tube Side
Separations Feed Stream Cooler
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
253 1032
Tube Side
2
Duty (MJ/hr)
125500
Description:
Prepared By: ACJ
21490 490800 0 2236100
0 240700 2236100 0
320 -50 -60 -5
126 123 220 217
0.87 2.58 1465 8.53
0.0212 0.0088 0.0000 0.0112
0.0000 1.9410 0.4134 0.0000
83.14 51.06 90.86 52.86
0.0645 0.0221 0.0000 0.0094
0.0000 0.1590 0.1273 0.0000
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
2438 1610
Duty (MJ/hr)
616400
Tube Side
Separations Feed Stream Cooler
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
Description:
Prepared By: ACJ
268300 236100 0 0
2122 34300 84711 84711
186 25 15 111
130 127 220 217
0.23 1.66 1015 988
0.0661 0.0180 0.0000 0.0000
0.2882 0.8904 1.1360 0.5442
38.64 37.82 75.44 79.03
0.0918 0.0256 0.0000 0.0000
0.0382 0.6110 0.5953 0.6432
Cooling Water
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
676 410
Tube Side
2
Duty (MJ/hr)
34360
Description:
Prepared By: ACJ
118700 118700 270400 270400
0 0 0 0
25 550 580 186
135 133 132 130
1.05 0.38 0.55 0.89
0.0153 0.0348 0.0318 0.0223
0.0000 0.0000 0.0000 0.0000
28.96 31.39 32.91 31.02
0.0516 0.1099 0.0546 0.0355
0.0000 0.0000 0.0000 0.0000
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
208 1037
Duty (MJ/hr)
97430
Tube Side
Nitrogen/Light Gases Exchanger
Shell Side
Process Streams
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Stainless Steel
Tube Side
Number of Passes 2
Description:
Prepared By: ACJ
151700 151700 268300 270400
0 0 2122 0
59 560 713 480
136 133 134 131
1.42 0.56 0.43 0.55
0.0204 0.0411 0.0393 0.0318
0.0000 0.0000 0.1910 0.0000
29.36 32.29 34.36 32.91
0.0284 0.0582 0.0684 0.0546
0.0000 0.0000 0.0382 0.0000
Process Streams
Shell Side
1
Stainless Steel
Unit Construction
Tube Side
Nitrogen/Air Exchanger
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
283 1052
Tube Side
2
Duty (MJ/hr)
81250
Description: Distillation Chain Feed Heater
Prepared By: ACJ
26 3657 20854 0
240700 237100 0 20854
-50 40 111 111
101 101 220 217
878 73.06 0.85 52.08
0.0081 0.0099 0.0125 0.0000
1.9440 0.5134 0.0000 0.2490
149.20 176.20 39.87 75.92
0.0174 0.0225 0.0254 0.0000
0.1590 0.1369 0.0000 0.6847
Heat Flux (kJ/hr-m
2
-K)
584 569
Tube Side
Unit Construction
Duty (MJ/hr)
36680
2
)
Exhaust Steam
Density (kg/m
3
)
Fluid Process Streams
Temperature (C)
Pressure (kPa)
Number of Passes
Stainless Steel
Shell Side
1
Carbon Steel
2
Description: Styrene Product Condenser
Prepared By: ACJ
112200 0 0 0
0 112200 601200 601200
61 44 15 34
5 5 220 217
0.20 885 1015 1001
0.0063 0.0000 0.0000 0.0000
0.0000 0.5634 1.1360 0.7332
137.00 184.70 75.44 76.14
0.0120 0.0000 0.0000 0.0000
0.0000 0.1411 0.5953 0.6237
Cooling Water
Shell Side
1
Carbon Steel
Unit Construction
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
5675 366
Tube Side
2
Duty (MJ/hr)
48142
Description:
Prepared By: ACJ
66800 66800 0 0
0 0 374100 374100
59 59 15 40
27 27 220 217
0.82 0.82 1015 996
0.0073 0.0073 0.0000 0.0000
0.0000 0.0000 1.1360 0.6514
105.30 105.30 75.44 76.15
0.0122 0.0122 0.0000 0.0000
0.0000 0.0000 0.5953 0.6315
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
1697 778
Duty (MJ/hr)
39440
Tube Side
Shell Side
Cooling Water
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
Description:
Prepared By: ACJ
0 0 29834 0
228500 228500 0 29834
96 96 111 111
27 27 220 217
818 818 0.85 52.08
0.0000 0.0000 0.0125 0.0000
0.3037 0.3037 0.0000 0.2490
205.00 205.00 39.87 75.92
0.0000 0.0000 0.0254 0.0000
0.1253 0.1253 0.0000 0.6847
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
3903 1073
Duty (MJ/hr)
66390
Tube Side
Shell Side
Exhaust Steam
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
Description:
Prepared By: ACJ
3673 3673 0 0
0 0 82220 82220
42 42 15 30
27 27 220 217
0.80 0.80 1015 1004
0.0073 0.0073 0.0000 0.0000
0.0000 0.0000 1.1360 0.7972
88.81 88.81 75.44 76.09
0.0109 0.0109 0.0000 0.0000
0.0000 0.0000 0.5953 0.6182
Cooling Water
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
370 780
Tube Side
2
Duty (MJ/hr)
5194
Description:
Prepared By: ACJ
0 0 1596 0
4252 4252 0 1596
70 70 111 111
27 27 220 217
822 822 0.85 52.08
0.0000 0.0000 0.0125 0.0000
0.3448 0.3448 0.0000 0.2490
167.90 167.90 39.87 75.92
0.0000 0.0000 0.0254 0.0000
0.1249 0.1249 0.0000 0.6847
Exhaust Steam
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
79 1076
Tube Side
2
Duty (MJ/hr)
3552
Description:
Prepared By: ACJ
103 103 0 0
0 0 52610 52610
33 33 15 28
27 27 220 217
0.90 0.90 1015 1005
0.0060 0.0060 0.0000 0.0000
0.0000 0.0000 1.1360 0.8418
141.80 141.80 75.44 76.03
0.0130 0.0130 0.0000 0.0000
0.0000 0.0000 0.5953 0.6147
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
453 612
Duty (MJ/hr)
2768
Tube Side
Shell Side
Cooling Water
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
Description:
Prepared By: ACJ
0 0 577 0
3570 3570 0 577
42 42 111 111
27 27 220 217
854 854 0.85 52.08
0.0000 0.0000 0.0125 0.0000
0.4838 0.4838 0.0000 0.2490
131.40 131.40 39.87 75.92
0.0000 0.0000 0.0254 0.0000
0.1266 0.1266 0.0000 0.6847
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
17 1080
Duty (MJ/hr)
1284
Tube Side
Shell Side
Exhaust Steam
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
Description:
Prepared By: ACJ
116100 116100 0 0
0 0 68340 68340
62 62 15 30
8 8 220 217
0.30 0.30 1015 1004
0.0064 0.0064 0.0000 0.0000
0.0000 0.0000 1.1360 0.7972
144.50 144.50 75.44 76.09
0.0124 0.0124 0.0000 0.0000
0.0000 0.0000 0.5953 0.6182
Cooling Water
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
11301 987
Tube Side
2
Duty (MJ/hr)
431700
Description:
Prepared By: ACJ
0 0 11519 0
112400 112400 0 11519
70 70 111 111
8 8 220 217
861 861 0.85 52.08
0.0000 0.0000 0.0125 0.0000
0.4197 0.4197 0.0000 0.2490
192.10 192.10 39.87 75.92
0.0000 0.0000 0.0254 0.0000
0.1348 0.1348 0.0000 0.6847
Exhaust Steam
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
10431 1063
Tube Side
2
Duty (MJ/hr)
461800
Description:
Prepared By: ACJ
78580 78580 0 0
0 0 208700 208700
61 61 15 42
5 5 220 217
0.20 0.20 1015 995
0.0063 0.0063 0.0000 0.0000
0.0000 0.0000 1.1360 0.6274
137.00 137.00 75.44 76.14
0.0120 0.0120 0.0000 0.0000
0.0000 0.0000 0.5953 0.6340
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
1046 755
Duty (MJ/hr)
23770
Tube Side
Shell Side
Cooling Water
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
Description:
Prepared By: ACJ
0 0 23911 0
33840 33840 0 23911
61 61 111 111
5 5 220 217
869 869 0.85 52.08
0.0000 0.0000 0.0125 0.0000
0.4635 0.4635 0.0000 0.2490
189.60 189.60 39.87 75.92
0.0000 0.0000 0.0254 0.0000
0.1370 0.1370 0.0000 0.6847
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
977 1073
Duty (MJ/hr)
53210
Tube Side
Shell Side
Exhaust Steam
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
Description:
Prepared By: ACJ
26940 26940 0 0
0 0 122000 122000
61 61 15 42
5 5 220 217
0.20 0.20 1015 995
0.0063 0.0063 0.0000 0.0000
0.0000 0.0000 1.1360 0.6274
137.00 137.00 75.44 76.14
0.0120 0.0120 0.0000 0.0000
0.0000 0.0000 0.5953 0.6340
Cooling Water
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
611 756
Tube Side
2
Duty (MJ/hr)
13900
Description:
Prepared By: ACJ
0 0 11073 0
6893 6893 0 11073
61 61 111 111
5 5 220 217
869 869 0.85 52.08
0.0000 0.0000 0.0125 0.0000
0.4641 0.4641 0.0000 0.2490
190.20 190.20 39.87 75.92
0.0000 0.0000 0.0254 0.0000
0.1369 0.1369 0.0000 0.6847
Exhaust Steam
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
453 1075
Tube Side
2
Duty (MJ/hr)
24640
Description:
Prepared By: ACJ
6715 6715 0 0
0 0 352400 352400
61 61 15 42
5 5 220 217
0.20 0.20 1015 995
0.0063 0.0063 0.0000 0.0000
0.0000 0.0000 1.1360 0.6274
137.00 137.00 75.44 76.14
0.0120 0.0120 0.0000 0.0000
0.0000 0.0000 0.5953 0.6340
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
1781 748
Duty (MJ/hr)
40140
Tube Side
Shell Side
Cooling Water
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
Description:
Prepared By: ACJ
0 0 19242 0
178 178 0 19242
73 73 111 111
5 5 220 217
838 838 0.85 52.08
0.0000 0.0000 0.0125 0.0000
0.4730 0.4730 0.0000 0.2490
228.50 228.50 39.87 75.92
0.0000 0.0000 0.0254 0.0000
0.1324 0.1324 0.0000 0.6847
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
239 4707
Duty (MJ/hr)
42820
Tube Side
Shell Side
Exhaust Steam
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
Description:
Prepared By: ACJ
498000 498000 0 0
0 0 1378200 1378200
-28 -47 -60 -50
174 171 220 217
2.22 2.41 1465 1437
0.0096 0.0089 0.0000 0.0000
0.0000 0.0000 0.4134 0.3730
40.06 38.83 90.86 92.12
0.0246 0.0225 0.0000 0.0000
0.0000 0.0000 0.1273 0.1230
R-22
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Light Gases Cooler
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
777 1615
Tube Side
2
Duty (MJ/hr)
14580
Description:
Prepared By: ACJ
497900 497900 0 0
0 0 67721 67721
-2 -25 -60 -50
3003 3000 220 217
34.71 38.00 1465 1437
0.0115 0.0107 0.0000 0.0000
0.0000 0.0000 0.4134 0.3730
41.84 40.24 90.86 92.12
0.0301 0.0277 0.0000 0.0000
0.0000 0.0000 0.1273 0.1230
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
1530 311
Duty (MJ/hr)
18600
Tube Side
Light Gases Cooler
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
ID Number: E-401.1 Date: 5/9/2006
Description:
Prepared By: ACJ
497900 497900 0 0
0 0 559980 559980
-30 -50 -60 -35
187 184 220 217
2.42 2.59 1465 1394
0.0096 0.0088 0.0000 0.0000
0.0000 0.0000 0.4134 0.3231
39.93 38.67 90.86 94.28
0.0244 0.0222 0.0000 0.0000
0.0000 0.0000 0.1273 0.1163
R-22
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Light Gases Cooler
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
429 1615
Tube Side
2
Duty (MJ/hr)
14920
ID Number: E-401.2 Date: 5/9/2006
Description:
Prepared By: ACJ
497900 497900 0 106200
0 0 106200 0
-13 -50 -60 -18
325 322 220 217
3.92 4.53 1465 8.95
0.0103 0.0089 0.0000 0.0107
0.0000 0.0000 0.4134 0.0000
41.09 38.67 90.86 51.52
0.0264 0.0223 0.0000 0.0088
0.0000 0.0000 0.1273 0.0000
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
447 1615
Duty (MJ/hr)
28470
Tube Side
Light Gases Cooler
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
ID Number: E-401.3 Date: 5/9/2006
Description:
Prepared By: ACJ
497900 497900 0 106200
0 0 106200 0
-13 -50 -60 -18
568 565 220 217
6.85 7.95 1465 8.95
0.0104 0.0089 0.0000 0.0107
0.0000 0.0000 0.4134 0.0000
41.09 38.67 90.86 51.52
0.0267 0.0226 0.0000 0.0088
0.0000 0.0000 0.1273 0.0000
R-22
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Light Gases Cooler
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
447 1615
Tube Side
2
Duty (MJ/hr)
28470
ID Number: E-401.4 Date: 5/9/2006
Description:
Prepared By: ACJ
497900 497900 0 0
0 0 1528700 1528700
-13 -48 -60 -43
997 994 220 217
12.01 13.89 1465 1418
0.0105 0.0092 0.0000 0.0000
0.0000 0.0000 0.4134 0.3497
41.09 38.80 90.86 93.02
0.0270 0.0233 0.0000 0.0000
0.0000 0.0000 0.1273 0.1201
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
886 1656
Duty (MJ/hr)
26740
Tube Side
Light Gases Cooler
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
ID Number: E-401.4 Date: 5/9/2006
Description:
Prepared By: ACJ
497900 497900 0 79263
0 0 79263 0
-11 -38 -60 -16
1750 1747 220 217
20.92 23.36 1465 8.89
0.0108 0.0098 0.0000 0.0107
0.0000 0.0000 0.4134 0.0000
41.22 39.40 90.86 51.73
0.0280 0.0251 0.0000 0.0089
0.0000 0.0000 0.1273 0.0000
R-22
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Light Gases Cooler
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
385 1615
Tube Side
2
Duty (MJ/hr)
21340
Description:
Prepared By: ACJ
463100 463100 0 53835
0 0 53835 0
6 -14 -60 -5
3003 3000 220 217
33.45 36.02 1465 8.53
0.0119 0.0112 0.0000 0.0112
0.0000 0.0000 0.4134 0.0000
41.84 40.50 90.86 52.86
0.0315 0.0293 0.0000 0.0094
0.0000 0.0000 0.1273 0.0000
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
323 1588
Duty (MJ/hr)
14840
Tube Side
Light Gases Cooler
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
ID Number: E-402.2 Date: 5/9/2006
Description:
Prepared By: ACJ
463100 463100 0 108120
0 0 108120 0
-9 -50 -60 -14
444 441 220 217
5.21 6.14 1465 8.82
0.0106 0.0090 0.0000 0.0108
0.0000 0.0000 0.4134 0.0000
40.86 38.28 90.86 51.93
0.0276 0.0230 0.0000 0.0090
0.0000 0.0000 0.1273 0.0000
R-22
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Light Gases Cooler
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
418 1616
Tube Side
2
Duty (MJ/hr)
29230
ID Number: E-402.3 Date: 5/9/2006
Description:
Prepared By: ACJ
463100 463100 0 114080
0 0 114080 0
-6 -50 -60 -11
846 843 220 217
9.85 11.73 1465 8.74
0.0108 0.0092 0.0000 0.0109
0.0000 0.0000 0.4134 0.0000
41.02 38.28 90.86 52.19
0.0282 0.0235 0.0000 0.0091
0.0000 0.0000 0.1273 0.0000
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
420 1615
Duty (MJ/hr)
31010
Tube Side
Light Gases Cooler
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
ID Number: E-402.4 Date: 5/9/2006
Description:
Prepared By: ACJ
463100 463100 0 80896
0 0 80896 0
-6 -37 -60 -11
1617 1614 220 217
18.83 21.28 1465 8.74
0.0110 0.0099 0.0000 0.0109
0.0000 0.0000 0.4134 0.0000
41.02 39.07 90.86 52.19
0.0289 0.0256 0.0000 0.0091
0.0000 0.0000 0.1273 0.0000
R-22
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Light Gases Cooler
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
359 1612
Tube Side
2
Duty (MJ/hr)
21990
Description:
Prepared By: ACJ
214100 214100 0 100160
0 0 100160 0
35 -50 -60 -5
3000 2997 220 217
26.03 35.86 1465 8.53
0.0149 0.0117 0.0000 0.0112
0.0000 0.0000 0.4134 0.0000
35.17 32.61 90.86 52.86
0.0442 0.0311 0.0000 0.0094
0.0000 0.0000 0.1273 0.0000
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
256 1617
Duty (MJ/hr)
27610
Tube Side
Light Gases Cooler
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
ID Number: E-403.1 Date: 5/9/2006
Description:
Prepared By: ACJ
214100 214100 0 0
0 0 154840 154840
-27 -50 -60 -32
397 394 220 217
4.30 4.71 1465 1384
0.0120 0.0110 0.0000 0.0000
0.0000 0.0000 0.4134 0.3130
33.27 32.61 90.86 94.85
0.0349 0.0319 0.0000 0.0000
0.0000 0.0000 0.1273 0.1147
R-22
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Light Gases Cooler
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
183 1609
Tube Side
2
Duty (MJ/hr)
7408
ID Number: E-403.2 Date: 5/9/2006
Description:
Prepared By: ACJ
214100 214100 0 100160
0 0 100160 0
35 -50 -60 -5
1088 1085 220 217
9.44 12.99 1465 8.53
0.0146 0.0112 0.0000 0.0112
0.0000 0.0000 0.4134 0.0000
35.17 32.61 90.86 52.86
0.0431 0.0324 0.0000 0.0094
0.0000 0.0000 0.1273 0.0000
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
257 1609
Duty (MJ/hr)
27610
Tube Side
Light Gases Cooler
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
Description:
Prepared By: ACJ
189700 189700 0 90583
0 0 90583 0
37 -50 -60 -5
3000 2997 220 217
24.98 34.70 1465 8.53
0.0153 0.0120 0.0000 0.0112
0.0000 0.0000 0.4134 0.0000
33.51 31.49 90.86 52.86
0.0466 0.0359 0.0000 0.0094
0.0000 0.0000 0.1273 0.0000
R-22
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Light Gases Cooler
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
229 1610
Tube Side
2
Duty (MJ/hr)
24970
ID Number: E-404.1 Date: 5/9/2006
Description:
Prepared By: ACJ
189700 189700 0 0
0 0 90583 90583
-32 -50 -60 -37
410 407 220 217
4.38 4.71 1465 16.18
0.0122 0.0114 0.0000 0.0000
0.0000 0.0000 0.4134 0.3282
31.88 31.49 90.86 94.02
0.0363 0.0338 0.0000 0.0000
0.0000 0.0000 0.1273 0.1171
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
160 53
Duty (MJ/hr)
168
Tube Side
Light Gases Cooler
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
ID Number: E-404.2 Date: 5/9/2006
Description:
Prepared By: ACJ
189700 189700 0 90583
0 0 90583 0
37 -50 -60 -5
1106 1103 220 217
9.21 12.77 1465 8.53
0.0150 0.0116 0.0000 0.0112
0.0000 0.0000 0.4134 0.0000
33.51 31.49 90.86 52.86
0.0456 0.0344 0.0000 0.0094
0.0000 0.0000 0.1273 0.0000
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
229 1610
Duty (MJ/hr)
24970
Tube Side
Light Gases Cooler
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
Description:
Prepared By: ACJ
171600 171600 0 82675
0 0 82675 0
38 -50 -60 -5
3000 2997 220 217
24.17 33.71 1465 8.53
0.0155 0.0123 0.0000 0.0112
0.0000 0.0000 0.4134 0.0000
32.12 30.58 90.86 52.86
0.0487 0.0375 0.0000 0.0094
0.0000 0.0000 0.1273 0.0000
R-22
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Light Gases Cooler
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
207 1610
Tube Side
2
Duty (MJ/hr)
22790
ID Number: E-405.1 Date: 5/9/2006
Description:
Prepared By: ACJ
171600 171600 0 0
0 0 160040 160040
-39 -50 -60 -45
427 424 220 217
4.60 4.77 1465 1423
0.0122 0.0117 0.0000 0.0000
0.0000 0.0000 0.4134 0.3546
30.74 30.58 90.86 92.82
0.0370 0.0356 0.0000 0.0000
0.0000 0.0000 0.1273 0.1207
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
145 1570
Duty (MJ/hr)
2571
Tube Side
Light Gases Cooler
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
ID Number: E-405.2 Date: 5/9/2006
Description:
Prepared By: ACJ
171600 171600 0 82675
0 0 82675 0
38 -50 -60 -5
1130 1127 220 217
9.10 12.67 1465 8.53
0.0153 0.0119 0.0000 0.0112
0.0000 0.0000 0.4134 0.0000
32.12 30.58 90.86 52.86
0.0478 0.0361 0.0000 0.0094
0.0000 0.0000 0.1273 0.0000
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
207 1610
Duty (MJ/hr)
22790
Tube Side
Light Gases Cooler
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
Description:
Prepared By: ACJ
156600 156600 0 76689
0 0 76689 0
40 -50 -60 -5
3000 2997 220 217
23.44 32.86 1465 8.53
0.0158 0.0125 0.0000 0.0112
0.0000 0.0000 0.4134 0.0000
31.10 29.92 90.86 52.86
0.0509 0.0392 0.0000 0.0094
0.0000 0.0000 0.1273 0.0000
R-22
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Light Gases Cooler
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
191 1608
Tube Side
2
Duty (MJ/hr)
21140
ID Number: E-406.1 Date: 5/9/2006
Description:
Prepared By: ACJ
156600 156600 0 76689
0 0 76689 0
-43 -50 -60 -48
436 433 220 217
4.64 4.75 1465 1432
0.0123 0.0120 0.0000 0.0000
0.0000 0.0000 0.4134 0.3662
30.00 29.92 90.86 92.36
0.0383 0.0373 0.0000 0.0000
0.0000 0.0000 0.1273 0.1222
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
145 1627
Duty (MJ/hr)
1605
Tube Side
Light Gases Cooler
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
ID Number: E-406.2 Date: 5/9/2006
Description:
Prepared By: ACJ
156600 156600 0 76689
0 0 76689 0
40 -50 -60 -5
1142 1139 220 217
8.92 12.48 1465 8.53
0.0155 0.0121 0.0000 0.0112
0.0000 0.0000 0.4134 0.0000
31.10 29.92 90.86 52.86
0.0500 0.0378 0.0000 0.0094
0.0000 0.0000 0.1273 0.0000
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
191 1608
Duty (MJ/hr)
21140
Tube Side
Light Gases Cooler
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
Description:
Prepared By: ACJ
145400 145400 0 71828
0 0 71828 0
41 -50 -60 -5
3000 2997 220 217
22.86 32.15 1465 8.53
0.0159 0.0126 0.0000 0.0112
0.0000 0.0000 0.4134 0.0000
30.23 29.36 90.86 52.86
0.0527 0.0406 0.0000 0.0094
0.0000 0.0000 0.1273 0.0000
R-22
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Light Gases Cooler
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
178 1607
Tube Side
2
Duty (MJ/hr)
19800
ID Number: E-407.1 Date: 5/9/2006
Description:
Prepared By: ACJ
145400 145400 0 1625
0 0 1625 0
-48 -50 -60 -5
448 445 220 217
4.76 4.77 1465 8.53
0.0123 0.0122 0.0000 0.0112
0.0000 0.0000 0.4134 0.0000
29.38 29.36 90.86 52.86
0.0392 0.0389 0.0000 0.0094
0.0000 0.0000 0.1273 0.0000
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
10 1735
Duty (MJ/hr)
448
Tube Side
Light Gases Cooler
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
Description:
Prepared By: ACJ
137800 137800 0 67257
0 0 67257 0
40 -50 -60 -5
3000 2997 220 217
22.55 31.62 1465 8.53
0.0160 0.0127 0.0000 0.0112
0.0000 0.0000 0.4134 0.0000
29.57 31.62 90.86 52.86
0.0538 0.0416 0.0000 0.0094
0.0000 0.0000 0.1273 0.0000
R-22
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Light Gases Cooler
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
167 1608
Tube Side
2
Duty (MJ/hr)
18540
ID Number: E-407.2 Date: 5/9/2006
Description:
Prepared By: ACJ
145400 145400 0 71828
0 0 71828 0
41 -50 -60 -5
448 445 220 217
8.82 12.38 1465 8.53
0.0157 0.0123 0.0000 0.0112
0.0000 0.0000 0.4134 0.0000
30.23 29.36 90.86 52.86
0.0518 0.0393 0.0000 0.0094
0.0000 0.0000 0.1273 0.0000
R-22
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Light Gases Cooler
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
178 1607
Tube Side
2
Duty (MJ/hr)
19800
ID Number: E-408.1 Date: 5/9/2006
Description:
Prepared By: ACJ
137800 137800 0 62904
0 0 62904 0
34 -50 -60 -5
1187 1184 220 217
9.09 12.49 1465 8.53
0.0156 0.0124 0.0000 0.0112
0.0000 0.0000 0.4134 0.0000
29.53 28.96 90.86 52.86
0.0522 0.0405 0.0000 0.0094
0.0000 0.0000 0.1273 0.0000
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
162 1610
Duty (MJ/hr)
17340
Tube Side
Light Gases Cooler
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
Description:
Prepared By: ACJ
133500 133500 0 63194
0 0 63194 0
37 -50 -60 -5
3000.0 2997.0 220.0 217.0
22.52 31.31 1465 8.53
0.0160 0.0128 0.0000 0.0112
0.0000 0.0000 0.4134 0.0000
29.17 28.72 90.86 52.86
0.0543 0.0423 0.0000 0.0094
0.0000 0.0000 0.1273 0.0000
Unit Construction
Fluid
2
)
Process Streams
Heat Flux (kJ/hr-m
2
-K)
127 2029
Duty (MJ/hr)
17420
Tube Side
Light Gases Cooler
Shell Side
R-22
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Shell Side
1
Carbon Steel
Tube Side
Number of Passes 2
ID Number: E-409.2 Date: 5/9/2006
Description:
Prepared By: ACJ
133500 133500 0 51295
0 0 51295 0
21 -50 -60 -5
1228 1225 220 217
9.73 12.80 1465 8.53
0.0152 0.0125 0.0000 0.0112
0.0000 0.0000 0.4134 0.0000
29.09 28.72 90.86 52.86
0.0512 0.0412 0.0000 0.0094
0.0000 0.0000 0.1273 0.0000
R-22
Shell Side
1
Carbon Steel
Unit Construction
Tube Side
Light Gases Cooler
Shell Side
Density (kg/m
3
)
Temperature (C)
Pressure (kPa)
Number of Passes
2
2
-K)
143 1612
Tube Side
2
Duty (MJ/hr)
14140
ID Number: P-100 Date: 5/8/2006
Description: Benzene Feed Pump Prepared By: MJH
No. Required 1 Checked By: JRB
Brake Power (hp) 2.5
Pump Efficiency (%) 75
Hydraulic Power (hp) 1.9
Design Pressure (kPa) 4000 (max)
Design Temperature (C) 300 (max)
Material of Construction Cast Iron
Process Fluid Mass Flow Rate (kg/hr) 97082
Pump Type Centrifugal
Orientation Horizontal
Inlet Pressure (kPa) 101.3
Outlet Pressure (kPa) 135.8
Inlet Temperature (C) 25.0
Outlet Temperature (C) 25.0
99.85% Benzene
Process Fluid Compsition (mol%) 0.1% n-Hexane
0.05% Toluene
A.3: Pump Specifications (1 of 4)
Pump Specifications
Fluid Properties
Description: Benzene Recycle Pump Prepared By: MJH
Process Fluid Mass Flow Rate (kg/hr)
Orientation
Pump Type
99.85% Benzene
0.14% n-Hexane
0.01% Toluene
Brake Power (hp)
Centrifugal
Horizontal
Cast Iron
3946
4000 (max)
300 (max)
75
0.25
0.33
Design Pressure (kPa)
Design Temperature (C)
Pump Efficiency (%)
Hydraulic Power (hp)
41.8
41.9
26.7
135.8
Process Fluid Compsition (mol%)
Pump Specifications
Fluid Properties
Description: Toluene Product Pump Prepared By: MJH
99.75% Toluene
Process Fluid Compsition (mol%) 0.24% Ethylbenzene
0.01% Benzene
Pump Specifications
Fluid Properties
Description: Styrene Product Pump Prepared By: MJH
0.01% Toluene
99.93% Styrene
Process Fluid Compsition (mol%) 0.04% Cumene
Trace Heavies
Pump Specifications
Fluid Properties
ID Number: Tank-100 Date: 5/8/2006
Description: Prepared By: MJH
No. Required 3 Checked By: MSB
External Cooler Type
Styrene Monomer Product Tank
Liquid Level (%) 88.5 Media H2O
Residence Time (days)
20
10
Tank Height (m)
Tank Diameter (m)
11,310
Type
Vessel Orientation
Y 36
Max Speed (rpm)
Heat Exchange?
Impeller Diameter (m)
NA
NA
Design Pressure (kPa)
Design Volume (m
3
)
4000 (max)
>99.93% Styrene Monomer
Agitation Required? N
Power (hp)
Carbon Steel
NA
A.4: Tank Specifications (1 of 8)
Tank Specifications
Operating Conditions
Fluid Composition (by mass)
Operating Temperature (C)
Operating Pressure (kPa)
Service Volume (m
3
)
Vertical
23.9
16.2
274
Atmospheric
10,010
Media Flowrate (kg/s)
Area (m
2
)
Cone Roof
Description: Styrene Monomer Off-Specification Tank Prepared By: MJH
Media Flowrate (kg/s) 11.2
Area (m
2
) 189
Liquid Level (%) 85 Media H2O
Residence Time (days) 2 Type External Cooler
Tank Height (m) 25 Heat Exchange? Y
Tank Diameter (m) 19 Max Speed (rpm) NA
Design Volume (m
3
) 7,090 Impeller Diameter (m) NA
Design Pressure (kPa) 4000 (max) Power (hp) NA
Design Temperature (C) 480 (max) Agitation Required? N
Vessel Orientation Vertical
Service Volume (m
3
) 6,008
Type Cone Roof
Operating Temperature (C) 23.9
Operating Pressure (kPa) Atmospheric
Tank Specifications
Fluid Composition (by mass) <99.93% Styrene Monomer
Description: Benzene Feed Tank Prepared By: MJH
Media Flowrate NA
Area (m
2
) NA
Liquid Level (%) 85 Media NA
Residence Time (days) 30 Type NA
Tank Height (m) 34 Heat Exchange? N
Design Volume (m
3
Service Volume (m
3
) 9,026
Type Cone Roof
Operating Temperature (C) Atmospheric
Tank Specifications
Fluid Composition (by mass) >99.8% Benzene
Description: Benzene Off-Specification Tank Prepared By: MJH
Media Flowrate NA
Area (m
2
) NA
Tank Height (m) 29.5 Heat Exchange? N
Design Volume (m
3
Service Volume (m
3
) 6,007
Type Cone Roof
Tank Specifications
Fluid Composition (by mass) <99.8% Benzene
Description: Ethylbenzene Startup Tank Prepared By: MJH
Media Flowrate NA
Area (m
2
) NA
Design Volume (m
3
Service Volume (m
3
) 13,274
Type Cone Roof
Tank Specifications
Fluid Composition (by mass) ~99.8% Ethylbenzene
Description: Ethylbenzene Off-Specification Tank Prepared By: MJH
Media Flowrate NA
Area (m
2
) NA
Design Volume (m
3
Service Volume (m
3
) 13,274
Type Cone Roof
Tank Specifications
Fluid Composition (by mass) <99.8% Ethylbenzene
Description: Toluene Product Storage Tank Prepared By: MJH
Media Flowrate NA
Area (m
2
) NA
Design Volume (m
3
Service Volume (m
3
) 1,177
Type Cone Roof
Tank Specifications
Fluid Composition (by mass) >99.7% Toluene
Description: Toluene Off-Spec Storage Tank Prepared By: MJH
Media Flowrate NA
Area (m
2
) NA
Tank Height (m) 11 Heat Exchange? N
Tank Diameter (m) 5.5 Max Speed (rpm) NA
Design Volume (m
3
) 261 Impeller Diameter (m) NA
Service Volume (m
3
) 236
Type Cone Roof
Tank Specifications
Fluid Composition (by mass) <99.7% Toluene
ID Number: V-100 Date: 5/11/2006
Description: Two-Phase Separator Prepared By: LJB
Vapor Feed
Vapor Effluent
Liquid Effluent
-50.0
124.0
N
A.5: Two Phase Separator Specifications (1 of 13)
Two-Phase Separator Specifications
Process Stream Conditions
Inlet Flows
Ethane (52.2%), Nitrogen (21.0%), Hydrogen (10.7%)
21490 kgmol/hr Ethylene (5.6%), Ethylbenzene (5.1%), Styrene (5.0%)
Trace: n-Hexane, Toluene, Benzene
Outlet Flows
Ethane (58.0%), Nitrogen (23.7%), Hydrogen (12.0%)
19080 kgmol/hr Ethylene (6.30%)
Ethylbenzene (45.2%), Styrene (44.7%), Ethane (5.6%),
2409 kgmol/hr Toluene (2.1%), Benzene (1.9%)
Trace: n-Hexane, Nitrogen, Heavies
Inlet Exit
Temperature (C) Temperature (C) -50.0
Pressure (kPa) Pressure (kPa) 124.0
Design Data
Type Two Phase Separator
Position Vertical
Height (m) 9.07
Diameter (m) 2.59
Volume (m
3
) 47.79
Additional Equipment
Heat Exchange Required? Agitation Required? N
Vapor Feed
Vapor Effluent
Liquid Effluent
25.0
128.8
N
Inlet Flows
Nitrogen (79.2%), Water (20.4%)
10380 kgmol/hr Trace: Carbon Dioxide
Outlet Flows
Water (100%)
1904 kgmol/hr
Inlet Exit
Temperature (C) Temperature (C) 25.0
Design Data
Position Vertical
Height (m) 6.93
Diameter (m) 1.98
Volume (m
3
) 21.34
Vapor Feed
Vapor Effluent
Liquid Effluent
-50.0
261.9
N
Inlet Flows
Outlet Flows
Nitrogen (99.4%)
Water (100%)
208.5 kgmol/hr Trace: Carbon Dioxide
Inlet Exit
Design Data
Position Vertical
Height (m) 4.27
Diameter (m) 1.22
Volume (m
3
) 4.99
Vapor Feed
Vapor Effluent
Liquid Effluent
-68.6
101.3
N
Inlet Flows
Ethane (58.0 mol%), Nitrogen (23.7%), Hydrogen (12.0%),
Outlet Flows
0 kgmol/hr
Inlet Exit
9.60 Height (m)
Design Data
Position Vertical
Volume (m
3
) 56.61
Diameter (m) 2.74
Vapor Feed
Vapor Effluent
Liquid Effluent
-115.3
101.3
N
Inlet Flows
Outlet Flows
Ethane (97.3%), Ethylene (2.7%)
1161 kgmol/hr Trace: Benzene, Nitrogen
Inlet Exit
Design Data
Position Vertical
Height (m) 8.00
Diameter (m) 2.29
Volume (m
3
) 32.95
Vapor Feed
Vapor Effluent
Liquid Effluent
-116.0
101.3
N
Inlet Flows
Outlet Flows
9642 kgmol/hr Ethylene 12.2%)
Ethane (100%)
8281 kgmol/hr
Inlet Exit
Design Data
Position Vertical
Height (m) 9.60
Diameter (m) 2.74
Volume (m
3
) 56.61
Vapor Feed
Vapor Effluent
Liquid Effluent
-123.1
101.3
N
Inlet Flows
9642 kgmol/hr Ethylene 12.2%)
Outlet Flows
Nitrogen (51.1%), Hydrogen (25.9%), Ethylene (13.3%)
8831 kgmol/hr Ethane (9.7 mol%)
Ethane (100%)
810.2 kgmol/hr
Inlet Exit
Design Data
Position Vertical
Height (m) 5.87
Diameter (m) 1.68
Volume (m
3
) 13.01
Vapor Feed
Vapor Effluent
Liquid Effluent
-132.0
101.3
N
Inlet Flows
8831 kgmol/hr Ethane (9.7%)
Outlet Flows
8222kgmol/hr Ethane (4.3%)
Ethane (82.6%), Ethylene (17.4%)
609 kgmol/hr
Inlet Exit
Design Data
Position Vertical
Height (m) 5.30
Diameter (m) 1.52
Volume (m
3
) 9.62
Vapor Feed
Vapor Effluent
Liquid Effluent
-136.2
101.3
N
Inlet Flows
8222kgmol/hr Ethane (4.3%)
Outlet Flows
Ethylene (74.0%), Ethane (26.0%),
524.9 kgmol/hr
Inlet Exit
Design Data
Position Vertical
Height (m) 5.33
Diameter (m) 1.52
Volume (m
3
) 9.67
Vapor Feed
Vapor Effluent
Liquid Effluent
-141.4
101.3
N
Inlet Flows
Outlet Flows
393.3 kgmol/hr
Inlet Exit
Design Data
Position Vertical
Height (m) 4.80
Diameter (m) 1.37
Volume (m
3
) 7.08
Vapor Feed
Vapor Effluent
Liquid Effluent
-147.9
101.3
N
Inlet Flows
Outlet Flows
7038 kgmol/hr Trace: Ethane
393.3 kgmol/hr
Inlet Exit
Design Data
Position Vertical
Height (m) 4.80
Diameter (m) 1.37
Volume (m
3
) 7.08
Vapor Feed
Vapor Effluent
Liquid Effluent
-155.6
101.3
N
Inlet Flows
7038 kgmol/hr Trace: Ethane
Outlet Flows
Nitrogen (65.6%), Hydrogen (33.2%)
6890 kgmol/hr Trace: Ethylene, Ethane
148.7 kgmol/hr
Inlet Exit
Design Data
Position Vertical
Height (m) 4.80
Diameter (m) 1.37
Volume (m
3
) 7.08
Vapor Feed
Vapor Effluent
Liquid Effluent
-163.4
101.3
N
Inlet Flows
Outlet Flows
58.1 kgmol/hr
Inlet Exit
Design Data
Position Vertical
Height (m) 4.27
Diameter (m) 1.22
Volume (m
3
) 4.99
ID Number: M-400 Date: 5/8/2006
Description: 1st Turbine Prepared By: MJH
No. Required 1 Checked By: LJB
Power Output (kW) 4739
23.67% Nitrogen
11.99% Hydrogen
Adiabatic Efficiency 85
Design Capacity (kg/hr) 549770
Expander Type Centrifugal
Inlet Temperature (C) -47.5
Outlet Temperature (C) -68.63
58.04% Ethane
6.30% Ethylene
Trace Amounts Heavies
A.6: Turbine Specifications (1 of 10)
Turbine Specifications
Fluid Properties
Process Feed Flow Rate (kg/hr) 497960
Description: 2nd Turbine Prepared By: MJH
6.30% Ethylene
Trace Amounts Heavies
58.04% Ethane
23.67% Nitrogen
Vapor Composition (mol%) 11.99% Hydrogen
Fluid Properties
Description: 3rd Turbine Prepared By: MJH
Stainless Steel
6.54% Ethylene
55.50% Ethane
25.20% Nitrogen
12.77% Hydrogen
Fluid Properties
Description: 4th Turbine Prepared By: MJH
Inlet Pressure (kPa) 3000
12.15% Ethylene
17.27% Ethane
56.84% Nitrogen
Fluid Properties
13.26% Ethylene
-50.0
9.68% Ethane
51.14% Nitrogen
Fluid Properties
12.96% Ethylene
-50.0
4.28% Ethane
54.93% Nitrogen
Fluid Properties
8.80% Ethylene
-50.0
2.80% Ethane
58.67% Nitrogen
Fluid Properties
5.25% Ethylene
-50.0
1.59% Ethane
61.83% Nitrogen
Fluid Properties
2.58% Ethylene
-50.0
0.74% Ethane
64.17% Nitrogen
Fluid Properties
0.97% Ethylene
-50.0
0.26% Ethane
65.55% Nitrogen
33.22% Hydrogen
Fluid Properties
ID Number: T-300 Date: 5/11/2006
Description: Toluene/Ethylbenzene Distillation Column Prepared By: MSB
No. Required 1 Checked By: ACJ
Function
Feed Fluid
Tray Type Flexipac HC
Tower Diameter (m) 2.12
Tower Height (m) 40.23
Design Temperature (C) 95.54
Design Pressure (kPa) 26.66
0.0000
0.0000
0.0000
0.0002 0.0000
0.4913
0.0012
0.0000
0.0000
0.0003
0.0000
0.0000
0.0003
0.0000
0.0128
0.0002
0.0000 0.0000
0.0000
0.0000
0.0000
0.0002
0.0001
H2O
Ethylene
0.0000
0.0000
0.0005
0.0002
0.0223
0.0000
Tower Construction
Number of Trays
Tray Spacing (in.)
Feed Tray 50
24
Flood Vapor Velocity (ft/s)
Design Vapor Vel. (ft/s)
A.7: Distillation Specifications (1 of 8)
Distillation Specifications
0
Composition (mol fraction)
Styrene
n-Bbenzene
Cumene
Temperature (C)
Pressure (kPa)
Height of Packing (m) 11.58
66
3.856
3.878
59.08
26.66
95.54
0.0202
0.4808
Oxygen
Nitrogen
Carbon
AMS
m-DiEBenzene
CO2
n-Pbenzene
Flow Rate (kg/hr)
Vapor Fraction
Feed
236400
0.4947
Distillate
7924
1
Methane
Ethane
n-Hexane
0.0020
0.0000
0.5014
0.0000
0.0000
0.0000
Bottoms
228500
0
Reflux Ratio
Pressure Drop (kPa)
Tray Efficiency 0.95
3.3
12
26.66
40
26.66
0.0000 0.0000
0.0000 0.0000
0.0000
0.0000
0.0000 0.0000
1M3-EBenzene
0.0000
0.0000 0.0000 0.0000
Toluene
Benzene
E-Benzene
Hydrogen
0.0000
0.0001
0.4958
0.0000 0.0000 0.0000
0.4754 0.0000
0.0000
0.0000
Description: Benzene/Toluene Distillation Column Prepared By: MSB
Function
Feed Fluid
Tray Type Sieve Tray
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.9975
0.0001
0.0024
0.0000
0.0000
0.0000
0.0254
0.0012
0.0000
0.0000
0.0000
0.0000
0.4947
0.4913
0.0128
0.0000 0.0000
0.0000 0.0000
n-Pbenzene
AMS
0.0000
0.0001
0.9745
0.0000 E-Benzene
Oxygen
n-Bbenzene
Ethylene
0.0000
69.54
0.0000
Reflux Ratio
Pressure Drop (kPa)
1.15
3.41
Bottoms
4252
0
Distillate
3673
1
Methane
26.66
59.08
0.0000
0.0000
0.0000
0.0000
n-Hexane
m-DiEBenzene
Pressure (kPa)
Flow Rate (kg/hr)
Vapor Fraction
Feed
7924
23
13.033
13.033
26.66 26.66
41.54
Ethane
Cumene
Temperature (C)
Hydrogen
1M3-EBenzene
Toluene
Benzene
1
CO2
Styrene
Carbon
H2O
Nitrogen
Tower Construction
Number of Trays
Tray Spacing (in.)
Feed Tray 10
24
0.0000
0.0000 0.0000
0.0000
0.0000 0.0000
0.0000 0.0000
0.0000 0.0000
0.0000 0.0000
Description: Ethylbenzene/Styrene Distillation Column Prepared By: MSB
Function
Feed Fluid
0.0000
0.0001
0.0000
0.0000
0.0000
0.0041
0.0000
0.0000
0.0000
0.0000
Pressure (kPa)
Tower Construction
112400 116100 228500
0.0000
0.0000
0.0000 0.0000
CO2
Styrene
n-Bbenzene
Ethylene
Cumene
AMS
Feed Tray 48
24
Flood Vapor Velocity (ft/s) Number of Trays
Tray Spacing (in.)
0
Feed
m-DiEBenzene
n-Pbenzene
0.0000 Ethane 0.0000
0.5014
0.0000
0.0000
Carbon
61.68
0.0000 0.0000
Temperature (C)
12.19
72
21.84
21.85
Height of Packing (m)
Methane
n-Hexane
Flow Rate (kg/hr)
Vapor Fraction
0.0000
1M3-EBenzene
Toluene
Benzene
E-Benzene
Distillate
1
0.0000
8.00
69.77
Bottoms
0
0.0000
0.0005
0.0000
0.0000
Reflux Ratio
Pressure Drop (kPa)
3.6
10
8.00 26.66
95.54
Oxygen 0.0000
0.0000
0.0000
0.0000
0.0000
H2O
0.9957
0.0000 0.0000 Hydrogen
Nitrogen 0.0000
0.0000
0.0000
0.4958 0.0002 0.9982
0.0000
0.0002
0.0020
0.0000
0.0000
0.0003 0.0000 0.0005
0.0000
0.0003 0.0000 0.0005
0.0000
0.0000
0.0002
0.0000 0.0000 0.0000
0.0001
Description: Styrene/Heavies Distillation Column Prepared By: MSB
Function
Feed Fluid
0.0002
0.0000
0.0000
0.0005
0.0000
0.0000
0.0005
0.0000
0.0000
0.0000
0.0000
0.0000 0.0007
0.0000 0.0000
0.0000 0.0000
0.0001 0.0013
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
0.0000 0.0000
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
0.0001 0.0001 0.0000
0.0000 0.0000 0.0000
0.0005
AMS
n-Hexane
0.0000 0.0000
0.9982 0.9994 0.9954
0.0000 0.0000
0.0000
5.33 8.00
45
Oxygen
0.0000
0.0003
0.0000
H2O
Nitrogen
n-Pbenzene
0.0000
0.0000
0.0000
Reflux Ratio
Pressure Drop (Psi.)
2.25
0.76 19.51 Height of Packing (m)
Distillate
78580
1
60.65
Bottoms
33840
0
0.0000
Feed
112400
Hydrogen
1M3-EBenzene
Toluene
Benzene
E-Benzene
Methane
5.33
Flow Rate (kg/hr)
Vapor Fraction
Ethane
0.0010
0.0000
0.0000
69.77
Cumene
Temperature (C)
Pressure (kPa)
0.0000
Carbon
60.6
m-DiEBenzene
0
CO2
Styrene
n-Bbenzene
Ethylene
0.0016
Tower Construction
Number of Trays
Tray Spacing (in.)
Feed Tray 24
24
22.573
22.575
Function
Feed Fluid
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
0.0016 0.0000 0.0078
0.0007 0.0000 0.0037
0.0010 0.0005 0.0028
0.0000 0.0000 0.0000
0.9954 0.9994 0.9798
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
0.0013 0.0001 0.0058
0.0000 0.0000
0.0000 0.0000
Tower Construction
Number of Trays
Tray Spacing (in.)
Feed Tray 16
24
19.51
18.93
18.93
0
CO2
Styrene
n-Bbenzene
Ethylene
Carbon
60.61 Temperature (C)
Pressure (kPa)
30
60.65
5.33 5.33
1.29
Flow Rate (kg/hr)
Vapor Fraction
Ethane
Feed
33840
Hydrogen
1M3-EBenzene
Toluene
Benzene
E-Benzene
Methane
Distillate
26940
1
5.33
60.82
Bottoms
6893
0
0.0000
0.0000
Oxygen
Reflux Ratio
1.5
m-DiEBenzene
n-Pbenzene
AMS
n-Hexane
Cumene
H2O
Nitrogen
Function
Feed Fluid
0.1632
0.0000 0.0000 0.0000
0.0037 0.0000
0.0000 0.0000 0.0004
0.1000 0.0028 0.0006
0.0000 0.0000 0.0000
0.1312 0.9798 0.9994
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
0.0000 0.0000 0.0000
0.0058 0.0000 0.2572
0.0000 0.0000 0.0000
0.0078 0.0000
0.0000
0.3480
0.0000 0.0000
0.0000 0.0000
0.0000
0.0000
0.0000
0.0000
m-DiEBenzene
n-Pbenzene
AMS
n-Hexane
Cumene
H2O
Nitrogen
5.33 5.33
15
Oxygen
Reflux Ratio
1.5
5.33
73.3
Bottoms
178
0
0.0000
0.0000
0.0000
0.0000
Distillate
6715
1
Feed
6893
Hydrogen
1M3-EBenzene
Toluene
Benzene
E-Benzene
Methane
Flow Rate (kg/hr)
Vapor Fraction
Ethane
Pressure (kPa)
30
60.82
Carbon
60.6 Temperature (C)
0.0000 0.0000
0
CO2
Styrene
n-Bbenzene
Ethylene
Tower Construction
Number of Trays
Tray Spacing (in.)
Feed Tray 16
24
17.07
4.571
4.614
Description: n-Hexane/Benzene Distillation Column Prepared By: MSB
Function
Feed Fluid
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.9985
0.0000
0.0000
0.0000
0.0000
0.0001
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.7520
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.2480
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0001
0.9745
0.0000
0.0000
0.0000
0.0000
0.0254
0.0000
Nitrogen
Tower Construction
Number of Trays
Tray Spacing (in.)
Feed Tray 28
24
Flood Vapor Velocity (ft/s) 40
7.976
1
CO2
Styrene
n-Bbenzene
Ethylene
Pressure (kPa)
Carbon
26.66
38.27
Benzene
E-Benzene
Methane
Ethane
41.51
Cumene
Temperature (C)
H2O
Flow Rate (kg/hr)
Vapor Fraction
Distillate
366.2
1
Feed
3673
41.82
Bottoms
3307
0
0.0000
0.0000
0.0014
0.0000
Reflux Ratio
2
15
26.66 26.66
3.449
m-DiEBenzene
n-Pbenzene
AMS
n-Hexane
Oxygen
Hydrogen
1M3-EBenzene
Toluene
ID Number: T-101 Date:
Description: Ethylbenzene Recovery Prepared By: MSB
Function
Feed Fluid
Tower Construction
0.0000
0.9340
0.0000
0.0000
0.0000
0.0660
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0002
0.0000
0.0000
0.0000
0.0000
0.0000
0.0009
0.0000
0.9982
0.0000
0.0000
0.0000
0.0000
0.0001
0.0004
0.0000
0.0000 0.0000
0.0004
0.0000
0.0000
193.9
135.8
Bottoms
37920
0
Feed Tray
0.0000 0.0000
0.0011
0.0000
0.0000
0.0000
0.1591
0.0000
0.2343
Flood Vapor Vel. (ft/s)
49
Nitrogen
Number of Trays
Tray Spacing (in.)
H2O
0.0000
0.0000
0.0000
0
CO2
Styrene
Flow Rate (kg/hr)
Vapor Fraction
Methane
0.0000
0.7444
0.0000
0.0094
0.8299
0.0000 0.0000
0.0000
0.0207
Ethane
Cumene
Temperature (C)
Hydrogen
1M3-EBenzene
Toluene
Benzene
Carbon
152.50
0.0000
155.6
0.0000
0.0000
0.0000
0.0000
Feed 1
111800
1
n-Hexane
m-DiEBenzene
Pressure (kPa)
E-Benzene
Oxygen
n-Bbenzene
Ethylene
3
135.8
4.793
4.793
135.8 135.9
12
24
Pressure Drop (kPa)
4.9
n-Pbenzene
AMS 0.0000
147.5
Reflux Ratio
0.0000
0.0000
0.0005
0.0000
0.0000
0.0000
0.0001
0.0000
0.0002
5/11/2006
0.0000
0.0000
0.0000
Feed 2
50190
0.0459
Distillate
124100
ID Number: R-100 Date: 5/8/2006
Description: Dehydrogenation Reactor Prepared By: MJH
No. Required 4 Checked By:
Vapor Feed
Vapor Effluent
451.2
260.3
N
Design Data
Temperature (C)
Pressure (kPa)
Temperature (C)
Pressure (kPa)
600.0
132.7
A.8: Reactor Specifications (1 of 4)
Reactor Specifications
Inlet Flows
Hydrogen (10.6%), Ethylene (5.6%), Styrene (5.0%)
Exit
19160 kgmol/hr
Ethane (64.6 mol%), Nitrogen (23.6%), Ethylbenzene (11.8%)
Trace: n-Hexane, Toluene, Styrene, Ethylene, Cumene
Diethylbenzene, Heavy Polyalkylates
Ethane (52.0 mol%), Nitrogen (21.0%), Ethylbenzene (5.1%)
Inlet
Trace: Benzene, Toluene, Cumene, Carbon, Polyalkylates
21540 kgmol/hr
Outlet Flows
Type Fluidized Catyst Cracking
Position Vertical
Tube Length (m)
3.8
38.3
Tube Diameter (m)
Stainless Steel
440.9 Volume (m
3
)
Description: Catalyst Regenerator Prepared By: MJH
Vapor Feed
Vapor Effluent
554.7
134.3
N
Vertical
Tube Length (m) 14.2
1.4 Tube Diameter (m)
Inlet Flows
Hydrogen (18.1 mol%), Oxygen (9.7%), Nitrogen (72.0%)
11408 kgmol/hr Trace: Ethane, Ethylene, Carbon
Type Regenerator
Position
Exit
10380 kgmol/hr
Temperature (C)
Pressure (kPa) 134.3
712.6
Trace: Carbon Dioxide
Inlet
Design Data
Volume (m
3
) 220.4
Outlet Flows
Nitrogen (79.2 mol%), Water (20.4%)
Pressure (kPa)
Temperature (C)
Description: Alkylation Reactor Prepared By: MJH
Vapor Feed
Vapor Effluent
Liquid Effluent
25.0
135.8
N
Void Volume (m
3
)
Packed Volume (m
3
)
0.7
0.3
Packed Diameter (m) 1.9
Packed Length (m) 6.5
Volume (m
3
) 124
Design Data
Type Distillation Reactor
Position Vertical
Trace: Cumene, Polyalkylates, Styrene
Inlet Exit
Outlet Flows
Ethylbenzene (79.4 mol%), Diethylbenzene (19.3%)
1008 kgmol/hr n-Butylbenzene (1.1%)
Ethane (99.99 mol%)
11060 kgmol/hr Trace: n-Hexane, Nitrogen, Ethylene
Ethane (83.5 mol%), Benzene (7.6%), Ethylene (8.9%)
31144 kgmol/hr Trace: n-Hexane, Toluene, Ethylbenzene, Nitrogen
Inlet Flows
Description: Transalkylator Prepared By: MJH
Liquid Feed
Liquid Effluent
121.4
135.8
N
Tube Diameter (m) 1.1
Tube Length (m) 19.1
Void Volume (m
3
) 0.75
Packed Volume (m
3
) 0.25
Volume (m
3
) 17
Design Data
Type Packed Bed
Position Vertical
Trace: Cumene, Toluene, Polyalkylates
Inlet Exit
Outlet Flows
Diethylbenzene (23.4 mol%), n-Butylbenzene (2.1%)
441 kgmol/hr Ethylbenzene (74.4%)
Diethylbenzene (93.4 mol%), n-Butylbenzene (6.6%)
441 kgmol/hr Trace: Cumene, Ethylbenzene, Toluene, Polyalkylates
Inlet Flows

Appendix B: PFD / PID / Layout
Ethylbenzene and Ethane
To Dehydrogenation
Benzene Feed
Benzene
From Separations
Ethylene and Ethane
From L.G. Separations
R-100
T-100
R-101
P-100
Byproducts
To Separations
1
49
12
100
101
104/
327
102
103
118
119
108
109
110
111
112
113/
324
114/
202
115
116
117
E-100
105/
452
106
B.1 PFD: Alkylation Unit Area 100
From Alkylation
Ethane Feed
Air Feed
Products
To Separations
Ethylbenzene
From Separations
R-200
R-
201
K-201
E-208
E-200
E-207
E-201
E-204 E-205
E-202
E-206
V-201
K-202
V-200
K-200
Water treatment
E-203
V-202
Light Gas
To L.G.Separations
Hydrogen and Nitrogen
200 201
114/
202
203/
316
204
205
206
207
208 209
210
212
211
213/
455
214
215
216 217
218
219
220
221
223 222
224
225
230
231
232 233 234
235/
301
236/
401
K-200
PFD pg. 6
PFD pg. 6
K-202
B.2 PFD: Dehydrogenation Unit Area 200
Purge
226
227
Products
From Dehydrogenation
Products
235/
301
453/
302
Benzene
To Alkylation
Ethylbenzene
To Dehydrogenation
P-301
K-303
Light Gases
Vented
Toluene For
Sale
E-300
Incinerated
P-302
inerts
Steam
Steam
T-300
T-303
Styrene Finish
To Separations pg. 2
inerts
inerts
Steam
T-301
inerts
Steam
T-302
315
314
313
312
311
310
309
308
307
306
305 304 303
203/
316
327
B.3 PFD: Separations Unit Area 300a
Steam
inerts
Steam
T-304
T-305
T-306
P-303
E-302
Steam
inerts
inerts
FC
E-301
318
317
315
Byproducts
From Alkylation
Heavy Byproducts
To Treatment
Styrene Finish
From Separations pg. 1
323
325
113/
324
322
321
320
319
329
328
B.4 PFD: Separations Unit Area 300b
to Customer
and Storage
Styrene
P-1017
P-1018
P-1019
Ethylene and Ethane
To Alkylation
Light Gas
E-400 K-400
M-400
V-400
236/
401
404 403 402
E-401 K-401
M-401
V-401 405 408 407 406
E-402 K-402
M-402
V-402 409 413 412 411
410 414
E-403 K-403
M-403
V-403 415 418 417 416
E-404 K-404
M-404
V-404 420 423 422 421
419
E-405 K-405
M-405
V-405 425 428 427 426
424 429
E-406 K-406
M-406
V-406 430 433 432 431
E-407 K-407
M-407
V-407 435 438 437 436
E-408 K-408
M-408
V-408 440 443 442 441
434 439 444
E-409 K-409
M-409
V-409 445 448 447 446
449
K-410
450 451
To Dehydrogenation
Products
To Separations
B.5 PFD: Light Gas SeparationsArea 400
105/
452
453/
302
E-410
454
213/
455
456
To Treatment
PFD pg. 6
PFD pg. 6
PFD pg. 6 PFD pg. 6 PFD pg. 6
PFD pg. 6 PFD pg. 6 PFD pg. 6
PFD pg. 6
Dehydrogenation
K-200
205
K-200.1 K-200.2 K-200.3 E-200.1
206
205.
3
205.
2
205.
1
Dehydrogenation
K-202
221
K-202.1 E-202.1 K-202.2
221.
1
221.
2
E-202.2
221.
3
222
L.G. Separations
K-401
K-401.1
405.
1
405
E-401.1 K-401.2
405.
3
405.
2
E-401.2
K-401.3
405.
5
405.
4
E-401.3 K-401.4
405.
7
405.
6
E-401.4
K-401.5
405.
9
405.
8
E-401.5 K-401.6
406
405.
10
L.G. Separations
K-402
K-402.1
409.
1
409
E-402.1 K-402.2
409.
3
409.
2
E-402.2
K-402.3
409.
5
409.
4
E-402.3 K-402.4
409.
7
409.
6
E-402.4
402.5
411
409.
8
L.G. Separations
K-403
K-403.1
415.
1
415
E-403.1 K-403.2
415.
3
415.
2
E-403.2
415.
4
K-403.3
416
L.G. Separations
K-404
K-404.1
420.
1
420
E-404.1 K-404.2
420.
3
420.
2
E-404.2
420.
4
K-404.3
421
L.G. Separations
K-405
K-405.1
425.
1
425
E-405.1 K-405.2
425.
3
425.
2
E-405.2
425.
4
K-405.3
426
L.G. Separations
K-406
K-406.1
430.
1
430
E-406.1 K-406.2
430.
3
430.
2
E-406.2
430.
4
K-406.3
431
L.G. Separations
K-407
K-407.1
435.
1
435
E-407.1 K-407.2
435.
3
435.
2
E-407.2
435.
4
K-407.3
436
L.G. Separations
K-408
K-408.1
440.
1
440
E-408.1 K-408.2
440.
3
440.
2
E-408.2
440.
4
E-408.3
441
K-409.1
445.
1
445
E-250 E-251
445.
3
445.
2
E-248
445.
4
E-252
446
L.G. Separations
K-409
B.6 PFD: PFD pg. 6 Compressor Chains
To Dehydrogenation
Benzene Feed
Benzene
From Separations
Ethylene and Ethane
R-100
T-100
R-101
P-100
Byproducts
To Separations
FC
1
49
12
FC
FC
100
101
104/
327
102
103
118
119
108
109
110
111
112
113/
324
114/
202
115
116
117
E-100
105/
452
106
LC
LC
V-93
B.7 P&ID: Alkylation Unit Area 100
FC
From Alkylation
Ethane Feed
Air Feed
Products
To Separations
Ethylbenzene
From Separations
R-200
R-
201
K-201
E-208
E-200
E-207
E-201
E-204
E-205
E-202
E-206
K-202
K-200
Water treatment
FC
FC PC
TC
TC
TC
TC
TC
TC
TC
E-203 TC
Light Gas
To L.G.Separations
200 201
114/
202
203/
316
204
205
206
207
208 209
210
212
211
213/
455
214
215
216 217
218
219
220
221
223 222
224
225
230
231
232 233 234
235/
301
236/
401
K-200
P&ID pg. 6
P&ID pg. 6
K-202
B.8 P&ID: Dehydrogenation Unit Area 200
FC
FC
Purge
226
227
Products
Products
235/
301
453/
302
Benzene
To Alkylation
Ethylbenzene
To Dehydrogenation
P-301
K-303
Light Gases
Vented
Toluene For
Sale
E-300
Incinerated
P-302
FC
PC
LC
inerts
TC
FC
LC
FC
PC
LC
TC
FC
LC
Steam
Steam
T-300
T-303
Styrene Finish
To Separations pg. 2
inerts
FC
PC
LC
inerts
TC
FC
LC
Steam
T-301
FC
PC
LC
inerts
TC
FC
LC
Steam
T-302
FC
315
314
313
312
311
310
309
308
307
306
305 304 303
203/
316
327
B.9 P&ID: Separations Unit Area 300a
PC
TC
FC
LC
Steam
inerts
PC
FC
LC
Steam
T-304
T-305
PC
FC
LC
T-306
E-181
E-101
Steam
inerts
inerts
LC
FC
E-301
FC
318
317
315
Byproducts
From Alkylation
Heavy Byproducts
To Treatment
Styrene Finish
From Separations pg. 1
323
326 325
113/
324
322
321
320
319
329
328
B.10 P&ID: Separations Unit Area 300b
FC
LC
TC
FC
LC
TC
Ethylene and Ethane
To Alkylation
Light Gas
E-400 K-400
M-400
V-400
236/
401
404 403 402
E-401 K-401
M-401
V-401
405 408 407 406
E-402 K-402
M-402
V-402
409 413 412 411
410 414
E-403 K-403
M-403
V-403
415 418 417 416
E-404 K-404
M-404
V-404
420 423 422 421
419
E-405 K-405
M-405
V-405
425 428 427 426
424 429
E-406 K-406
M-406
V-406
430 433 432 431
E-407 K-407
M-407
V-407
435 438 437 436
E-408 K-408
M-408
V-408
440 443 442 441
434 439 444
E-409 K-409
M-409
V-409
445 448 447 446
449
K-410
450 451
To Dehydrogenation
Products
To Separations
B.11 P&ID: Light Gas SeparationsArea 400
105/
452
453/
302
E-410
454
213/
455
456
To Treatment
P&ID pg. 6
P&ID pg. 6
P&ID pg. 6 P&ID pg. 6 P&ID pg. 6
P&ID pg. 6 P&ID pg. 6 P&ID pg. 6
P&ID pg. 6
Dehydrogenation
K-200
205
K-200.1 K-200.2 K-200.3 E-200.1
206
205.
3
205.
2
205.
1
Dehydrogenation
K-202
221
K-202.1 E-202.1 K-202.2
221.
1
221.
2
E-202.2
221.
3
222
L.G. Separations
K-401
K-401.1
405.
1
405
E-401.1 K-401.2
405.
3
405.
2
E-401.2
K-401.3
405.
5
405.
4
E-401.3 K-401.4
405.
7
405.
6
E-401.4
K-401.5
405.
9
405.
8
E-401.5 K-401.6
406
405.
10
L.G. Separations
K-402
K-402.1
409.
1
409
E-402.1 K-402.2
409.
3
409.
2
E-402.2
K-402.3
409.
5
409.
4
E-402.3 K-402.4
409.
7
409.
6
E-402.4
402.5
411
409.
8
L.G. Separations
K-403
K-403.1
415.
1
415
E-403.1 K-403.2
415.
3
415.
2
E-403.2
415.
4
K-403.3
416
L.G. Separations
K-404
K-404.1
420.
1
420
E-404.1 K-404.2
420.
3
420.
2
E-404.2
420.
4
K-404.3
421
L.G. Separations
K-405
K-405.1
425.
1
425
E-405.1 K-405.2
425.
3
425.
2
E-405.2
425.
4
K-405.3
426
L.G. Separations
K-406
K-406.1
430.
1
430
E-406.1 K-406.2
430.
3
430.
2
E-406.2
430.
4
K-406.3
431
L.G. Separations
K-407
K-407.1
435.
1
435
E-407.1 K-407.2
435.
3
435.
2
E-407.2
435.
4
K-407.3
436
L.G. Separations
K-408
K-408.1
440.
1
440
E-408.1 K-408.2
440.
3
440.
2
E-408.2
440.
4
E-408.3
441
K-409.1
445.
1
445
E-250 E-251
445.
3
445.
2
E-248
445.
4
E-252
446
L.G. Separations
K-409
FC
F
TC
PC
Controls for each Compressor and
Heat Exchanger in the Process
B.12 P&ID: P&ID pg. 6 Compressor Chains
V-403
V-404
V-406
V-402
V-408
V-405
V-400
V-401
V-407
T-300
T-301
T-303
T-304
T-305
T-
30
2
T-306
2.12m.
0.80m. 0.80m.
0.34m.
5.63m.
5.61m.
3.59m.
3.64m.
Dehydro Dehydro Dehydrogenation
Dehydrogenation Dehydrogenation
Dehydrogenation
3.80m. 3.80m.
3.80m. 3.80m.
Alkylator
Trans
Akylator
Alkylation Tower
Trans
Akylator
Trans
Akylator
Trans
Akylator
1.90m. 1.90m.
3.55m.
1.10m. 1.10m. 1.10m. 1.10m. 1.10m. 1.10m. 1.10m.
Alkylator
1.90m. 1.90m.
Alkylator
1.90m. 1.90m.
Alkylator
1.90m. 1.90m.
AREA 100 --
ALKYLATION
AREA 300 --
SEPARATIONS
AREA 400
LIGHT GASES SEPARATION
AREA 200 --
DEHYDROGENATION
V-409
FRONT
B.13: Plant Layout
Dehydro Dehydro Dehydro Dehydro
T-300
T
-
3
0
2
T-304
T-306
V-
40
7
V-
40
8
V-
40
9
T
-
3
0
1
Alkyl
ator
Alkyl
ator
Alkyl
ator
Alkyl
ator
Alkylation
Tower
V-400
V-
40
6
V-
40
5
V-
40
4
V-402
V-401
V-
403
Tr
a
n
s
Al
k
yl
at
or
Tr
a
n
s
Al
k
yl
at
or
Tr
a
n
s
Al
k
yl
at
or
Tr
a
n
s
Al
k
yl
at
or
1
0
.
0
0
m
.
1
0
.
0
0
m
.
1
0
.
0
0
m
.
1
0
.
0
0
m
.
1
0
.
0
0
m
.
B.14: Plant Layout, Front View

Appendix C: Separations
Flv 0.914 =
Flv
Wl
Wv
|
\
|
|
v
l
|
\
|
|
0.5
:=
Wl
Wv
28.833 =
Wv V MWv :=
Wl L MWl :=
NumberOfTrays 66 :=
lb
ft
3
l 51.077 :=
lb
ft
3
v 5.1336 10
2
:=
dyne
cm
21.913 :=
lbmol
hr
V 205.1 :=
lbmol
hr
L 4791 :=
cP v 7.3254 10
3
:=
lb
lbmol
MWl 105.15 :=
lb
lbmol
MWv 85.187 :=
K T 368.69 := R 1.314 := atm P 0.2631 :=
atm ft
3
lbmol K
Calculations for Column Diameter in Separations Unit : Tray Column T-300 Bottom of Column
C.1: Separations Hand Calculations (1 of 3)
m Diameter 2.012 =
Diameter Dia
30.48
100
|
\
|
|
:=
ft Dia 6.6 =
Dia
4 V MWv ( )
v fraction uflood 3600
( )
0.5
:=
0.95 :=
Finding the Diameter using equation 12-14 Wankat
uop 2.909 =
uop fraction ( ) uflood :=
fraction 0.75 :=
uflood 3.878 =
uflood K
l v
v
|
\
|
|
0.5
:=
l 51.077 =
v 0.051 =
K 0.123 =
K Csb
20
|
\
|
|
0.2
:=
Csb 0.121 =
Csb 10
logCsb
:=
Finding Csb:
logCsb .94506 0.70234 log Flv ( ) 0.22618 log Flv ( ) ( )
2
:=
From Wankat equation 12-10e for 24-in tray spacing
Flv 0.914 =
Flv
Wl
Wv
|
\
|
|
v
l
|
\
|
|
0.5
:=
Wl
Wv
28.833 =
Wv V MWv :=
Wl L MWl :=
NumberOfTrays 66 :=
lb
ft
3
l 51.077 :=
lb
ft
3
v 5.1336 10
2
:=
dyne
cm
21.913 :=
lbmol
hr
V 205.1 :=
lbmol
hr
L 4791 :=
cP v 7.3254 10
3
:=
lb
lbmol
MWl 105.15 :=
lb
lbmol
MWv 85.187 :=
K T 363.45 := R 1.314 := atm P 0.2631 :=
atm ft
3
lbmol K
Calculations for Column Diameter in Separations Unit : Tray Column T-300 Middle of Column
m Diameter 2.012 =
Diameter Dia
30.48
100
|
\
|
|
:=
ft Dia 6.6 =
Dia
4 V MWv ( )
( )
0.5
:=
0.95 :=
uop 2.909 =
fraction 0.75 :=
uflood 3.878 =
uflood K
l v
v
|
\
|
|
0.5
:=
l 51.077 =
v 0.051 =
K 0.123 =
K Csb
20
|
\
|
|
0.2
:=
Csb 0.121 =
Csb 10
logCsb
:=
Finding Csb:
2
:=
Flv 0.914 =
Flv
Wl
Wv
|
\
|
|
v
l
|
\
|
|
0.5
:=
Wl
Wv
28.833 =
Wv V MWv :=
Wl L MWl :=
NumberOfTrays 66 :=
lb
ft
3
l 51.077 :=
lb
ft
3
v 5.1336 10
2
:=
dyne
cm
21.913 :=
lbmol
hr
V 205.1 :=
lbmol
hr
L 4791 :=
cP v 7.3254 10
3
:=
lb
lbmol
MWl 105.15 :=
lb
lbmol
MWv 85.187 :=
K T 332.23 := R 1.314 := atm P 0.2631 :=
atm ft
3
lbmol K
Calculations for Column Diameter in Separations Unit : Tray Column T-300 Top of Column
m Diameter 2.012 =
Diameter Dia
30.48
100
|
\
|
|
:=
ft Dia 6.6 =
Dia
4 V MWv ( )
( )
0.5
:=
0.95 :=
uop 2.909 =
fraction 0.75 :=
uflood 3.878 =
uflood K
l v
v
|
\
|
|
0.5
:=
l 51.077 =
v 0.051 =
K 0.123 =
K Csb
20
|
\
|
|
0.2
:=
Csb 0.121 =
Csb 10
logCsb
:=
Finding Csb:
2
:=
C.2: Estimates of Column Height (1 of 3)
Separations Unit at 100% Capacity
T-300 Toluene/EB Column T-302 n-Hexane/Benzene Split
Pressure 0.2666 bar Pressure 0.267 bar
1.0133 bar/atm 1.013 bar/atm
0.2631 atm 0.263 atm
deg Celsius K deg Celsius K
Top 59.08 332.23 Top 38.27 311.42
Middle 90.3 363.45 Middle 41.51 314.66
Bottom 95.54 368.69 Bottom 41.82 314.97
Average 81.64 354.79 Average 40.53 313.68
Tray Spacing 24 in. Tray Spacing 24 in.
Number of Trays 66 Number of Trays 40
Column Height 1584 in. 132 ft Column Height 960 in. 80.00 ft
39.37 in./m 39.37 in./m
40.23 m 24.38 m
Column Diameter Column Diameter
Top 2.12 m 6.96 ft Top 0.34 m 1.10 ft
Based on Previous Models the Diameter of the
Total Column will be assumed to not change drastically
because changes in temperature are minimal
Diameter of Packing 1.31 m 4.29 ft
According to vendor information KOCH-GLITSCH
Column diameter range is from 3-9ft or 1.0-2.7m
T-301 Benzene/Toluene Column T-303 EB/Styrene Column
0.2631 atm 0.079 atm
Top 41.51 314.66 Top 61.68 334.83
Middle 58.17 331.32 Middle 62.42 335.57
Bottom 69.54 342.69 Bottom 69.77 342.92
Average 56.41 329.56 Average 64.62 337.77
Number of Trays 23 46.00 ft Number of Trays 72
Column Height 552 in. Column Height 1728 in. 144 ft
39.37 in./m 39.37 in./m
14.02 m 43.89 m
Top 0.80 m 0.00 ft Top 5.63 m 18.47 ft
Column diameter range is from 7.5-over 29ft or 2.3-~9m
Styrene Finish
T-304 T-306
0.053 atm 0.053 atm
Top 60.6 333.75 Top 60.6 333.75
Middle 60.61 333.76 Middle 60.69 333.84
Bottom 60.65 333.8 Bottom 73.3 346.45
Average 60.62 333.77 Average 64.86 338.01
Number of Trays 45 Number of Trays 30
Column Height 1080 in. 90.00 ft Column Height 720 in. 60.00 ft
39.37 in./m 39.37 in./m
27.43 m 18.29 m
Top 5.61 m 18.41 ft Top 3.64 m 11.96 ft
Diameter of Packing 5.88 m 19.27 ft Diameter of Packing 1.72 m 5.63 ft
According to vendor information KOCH-GLITSCH According to vendor information KOCH-GLITSCH
Column diameter range is from 7-17.5ft or 2.1-~5.3m Column diameter range is from 7-17.5ft or 2.1-~5.3m
T-305
Pressure 0.053 bar
1.013 bar/atm
0.053 atm
deg Celsius K
Top 60.61 333.76
Middle 60.63 333.78
Bottom 60.82 333.97
Average 60.69 333.84
Tray Spacing 24 in.
Number of Trays 30
Column Height 720 in. 60.00 ft
39.37 in./m
18.29 m
Column Diameter
Top 3.59 m 11.77 ft
Column diameter range is from 7-17.5ft or 2.1-~5.3m
Alkylation Unit
T-101
Pressure 1.358 bar
1.013 bar/atm
1.340 atm
deg Celsius K
Top 147.5 420.65
Middle 193.8 466.95
Bottom 193.9 467.05
Average Temp 178.4 451.55
Tray Spacing 24 in.
Number of Trays 49
Column Height 1176 in. 98.00 ft
39.37 in./m
29.87 m
Column Diameter
Top 3.55 m 11.65 ft
C.3: Fenske Equation (1 of 3)
Hand Calculations for Minimum Reflux using Fenske's equation
Mix 3 going into separations B-100 Ethylbenzene/Styrene Split
By Products MW Bp K alpha Mol fraction By Products MW Bp K alpha Mol fraction
Hydrogen 2.02 -252.6 8.72E+03 0.0000 Hydrogen 2.02 -252.6 8.72E+03 0.0000
Nitrogen 28.01 -195.8 4.31E+03 2.02 0.0000 Nitrogen 28.01 -195.8 4.31E+03 2.02 0.0000
Ethylene 28.05 -103.75 3.11E+02 13.84 0.0000 Ethylene 28.05 -103.75 3.11E+02 13.84 0.0000
Ethane 30.07 -88.6 2.46E+02 1.27 0.0000 Ethane 30.07 -88.6 2.46E+02 1.27 0.0000
n-Hexane 86.18 68.73 1.18E+00 207.78 0.0005 n-Hexane 86.18 68.73 1.18E+00 207.78 0.0000
Benzene 78.11 80.09 7.85E-01 1.51 0.0200 Benzene 78.11 80.09 7.85E-01 1.51 0.0000
Toluene 92.14 110.65 2.70E-01 2.91 0.0223 Toluene 92.14 110.65 2.70E-01 2.91 0.0021
Ethylbenzene 106.17 136.2 1.01E-01 2.67 0.4821 Ethylbenzene 106.17 136.2 1.01E-01 2.67 0.5025
Styrene 104.15 145.16 6.86E-02 1.47 0.4744 Styrene 104.15 145.16 6.86E-02 1.47 0.4945
cumene 120.19 152.41 4.39E-02 1.56 0.0002 cumene 120.19 152.41 4.39E-02 1.56 0.0002
n-p-benzene 120.19 159.24 8.49E-03 5.17 0.0000 n-p-benzene 120.19 159.24 8.49E-03 5.17 0.0000
1M3-EBenzene 120.19 161.33 3.52E-02 0.24 0.0002 1M3-EBenzene 120.19 161.33 3.52E-02 0.24 0.0002
-methylstyrene 118.18 165.5 2.70E-02 1.31 0.0002 -methylstyrene 118.18 165.5 2.70E-02 1.31 0.0002
m-DiEBenzene 134.22 181.14 1.30E-02 2.07 0.0001 m-DiEBenzene 134.22 181.14 1.30E-02 2.07 0.0001
n-Butyl-Benzene 134.22 183.3 9.95E-03 1.31 0.0000 n-Butyl-Benzene 134.22 183.3 9.95E-03 1.31 0.0000
All taken from HYSYS
The closer to 1 the harder to separate Vent Gas Distillate
Distillate Bottoms
T-300 Bottoms T-303
BEB 7.79
TS 3.93
BT 2.91
TEB 2.67
TT 1.00
EBEB 1.00
EBT 0.37
SEB 0.68
z
B 0.0200 z
T 2.11E-03
z
EB 0.4821 z
S 0.49
z
T 0.0223 z
EB 0.50
FR
A,dist 0.9999 FR
A,dist 0.98
FR
B,dist 0.9999 FR
B,dist 0.98
N
min 19 N
min 20
FR
C,dist 0.9999 FR
C,dist 1.00
Styrene/Cumene Split Styrene/Cumene Split
By Products MW Bp K alpha Mol fraction By Products MW Bp K alpha Mol fraction
Hydrogen 2.02 -252.6 8.72E+03 0.0000 Hydrogen 2.02 -252.6 8.72E+03 0.0000
Nitrogen 28.01 -195.8 4.31E+03 2.02 0.0000 Nitrogen 28.01 -195.8 4.31E+03 2.02 0.0000
Ethylene 28.05 -103.75 3.11E+02 13.84 0.0000 Ethylene 28.05 -103.75 3.11E+02 13.84 0.0000
Ethane 30.07 -88.6 2.46E+02 1.27 0.0000 Ethane 30.07 -88.6 2.46E+02 1.27 0.0000
n-Hexane 86.18 68.73 1.18E+00 207.78 0.0000 n-Hexane 86.18 68.73 1.18E+00 207.78 0.0000
Benzene 78.11 80.09 7.85E-01 1.51 0.0000 Benzene 78.11 80.09 7.85E-01 1.51 0.0000
Toluene 92.14 110.65 2.70E-01 2.91 0.0000 Toluene 92.14 110.65 2.70E-01 2.91 0.0000
Ethylbenzene 106.17 136.2 1.01E-01 2.67 0.0001 Ethylbenzene 106.17 136.2 1.01E-01 2.67 0.0000
Styrene 104.15 145.16 6.86E-02 1.47 0.9982 Styrene 104.15 145.16 6.86E-02 1.47 0.9955
cumene 120.19 152.41 4.39E-02 1.56 0.0005 cumene 120.19 152.41 4.39E-02 1.56 0.0010
n-p-benzene 120.19 159.24 8.49E-03 5.17 0.0000 n-p-benzene 120.19 159.24 8.49E-03 5.17 0.0000
1M3-EBenzene 120.19 161.33 3.52E-02 0.24 0.0005 1M3-EBenzene 120.19 161.33 3.52E-02 0.24 0.0013
-methylstyrene 118.18 165.5 2.70E-02 1.31 0.0005 -methylstyrene 118.18 165.5 2.70E-02 1.31 0.0016
m-DiEBenzene 134.22 181.14 1.30E-02 2.07 0.0002 m-DiEBenzene 134.22 181.14 1.30E-02 2.07 0.0007
n-Butyl-Benzene 134.22 183.3 9.95E-03 1.309709 0.0000 n-Butyl-Benzene 134.22 183.3 9.95E-03 1.309709 0.0000
Distillate T-305 Distillate
Bottoms
EBC 2.30 Bottoms
T-304
EBS 1.47
EBC 2.30
SS 1.00
EBS 1.47
CS 0.64
SS 1.00 z
EB 0.000
CS 0.64 z
C 0.001
z
EB 0.000 z
S 1.00
z
C 0.001 FR
A,dist 0.9993
z
S 1.00 FR
B,dist 0.9993
FR
A,dist 0.9993 N
min 32
FR
B,dist 0.9993 FR
C,dist 1.00
N
min 32
FR
C,dist 1.00
Styrene/Cumene Split
By Products MW Bp K alpha Mol fraction
Hydrogen 2.02 -252.6 8.72E+03 0.0000
Nitrogen 28.01 -195.8 4.31E+03 2.02 0.0000
Ethylene 28.05 -103.75 3.11E+02 13.84 0.0000
Ethane 30.07 -88.6 2.46E+02 1.27 0.0000
n-Hexane 86.18 68.73 1.18E+00 207.78 0.0000
Benzene 78.11 80.09 7.85E-01 1.51 0.0000
Toluene 92.14 110.65 2.70E-01 2.91 0.0000
Ethylbenzene 106.17 136.2 1.01E-01 2.67 0.0000
Styrene 104.15 145.16 6.86E-02 1.47 0.9800
cumene 120.19 152.41 4.39E-02 1.56 0.0028
n-p-benzene 120.19 159.24 8.49E-03 5.17 0.0005
1M3-EBenzene 120.19 161.33 3.52E-02 0.24 0.0057
-methylstyrene 118.18 165.5 2.70E-02 1.31 0.0078
m-DiEBenzene 134.22 181.14 1.30E-02 2.07 0.0000
n-Butyl-Benzene 134.22 183.3 0.0099538 1.309709 0.0037
T-306
EBC 2.30 Distillate
EBS 1.47 Bottoms
SS 1.00
CS 0.64
z
EB 0.000
z
C 0.003
z
S 0.98
FR
A,dist 0.9983
FR
B,dist 0.9983
N
min 28
FR
C,dist 1.00
C.4: Dimensioning of Packed Columns (1 of 2)
Values used in Calculation the Diameter of the Packed Column
At 100% Capacity
T-300 T-303
Molar Mass: Liquid Vapor Molar Mass: Liquid Vapor
Molar Mass (kg/kgmole) 105.15 85.19 Molar Mass (kg/kgmole) 104.18 106.11
Surface tension Surface tension
dyne/cm 21.913 dyne/cm 25.695
kg/s2 0.021913 kg/s2 0.025695
Viscosity Viscosity
cP 0.30367 0.007325 cP 0.41967 0.0063562
kg/m*s 3.04E-04 7.33E-06 kg/m*s 4.20E-04 6.3562E-06
Flows Flows
kmol/h 2421 102.8 kmol/h 1199 1222
kmol/s 0.6725 0.0286 kmol/s 0.3331 0.3394
T-304 T-305
Molar Mass: Liquid Vapor Molar Mass: Liquid Vapor
Molar Mass (kg/kgmole) 104.23 104.16 Molar Mass (kg/kgmole) 104.51 104.16
Surface tension Surface tension
dyne/cm 26.67 dyne/cm 26.619
kg/s2 0.02667 kg/s2 0.026619
Viscosity Viscosity
cP 0.46345 0.006295 cP 0.46407 0.0062951
kg/m*s 4.63E-04 6.30E-06 kg/m*s 4.64E-04 6.30E-06
Flows Flows
kmol/h 360.7 838.3 kmol/h 73.27 287.4
kmol/s 0.100194 0.23286 kmol/s 0.02035 0.07983
C.4: Dimensioning of Packed Columns (2 of 2)
T-306
Molar Mass: Liquid Vapor
Molar Mass (kg/kgmole) 119.68 104.16
Surface tension
dyne/cm 23.651
kg/s2 0.023651
Viscosity
cP 0.47297 0.006295
kg/m*s 4.73E-04 6.30E-06
Flows
kmol/h 1.634 71.64
kmol/s 0.000454 0.0199
kg
m s
Viscosity g 7.33 10
6
:=
kg
m s
Liqflow 0.6725 :=
Gasflow 0.0286 :=
kmol
s
kmol
s
Assumption of Operational gas flow rate:
Flow 2.0 := Pa
0.5
ug
Flow
g
0.5
( )
:=
m
s
ug 2.205 =
Vg Gasflow
Mg
g
:=
Vg 2.963 =
m
3
s
C.5: Dimensioning a Packed Column
Taken from Fair, J. and Stichlmair, J. p. 457
Liquid Phase Gas Phase
kg
kmol
Molar Mass Ml 105.15 :=
kg
kmol
Mg 85.19 :=
kg
m
3
Density l 818.17 :=
kg
m
3
g 0.82233 :=
Surface Tension 0.021913 :=
kg
s
2
l 3.04 10
4
:=
Cross section Ac
Ac
Vg
ug
:=
Ac 1.343 = m
2
Dc 4
Ac
0.5
:=
Dc 1.308 = m
C.6: Summary of All Columns in the Process
Separations Unit
Column Height (m) Column Diameter (m) Packing Height (m) Packing Diameter (m)
T-300 40.23 2.12 11.58 1.31
T-301 14.02 0.80
T-302 24.38 0.34
T-303 43.89 5.63 12.19 6.38
T-304 27.43 5.61 19.51 5.88
T-305 18.29 3.59 19.51 3.44
T-306 18.29 3.64 17.07 1.72
Alkylation Unit
Column Height (m) Column Diameter (m)
T-101 29.87 3.55
HETP assumed as 2 ft
C.7: Optimization Reflux Ratio (1 of 6)
The amount of EB recovered is not a specification in this optimization due to the degrees of freedom restriction on the distillation columns
Minimum Reflux From HYSYS Shortcut Calculation
Column 100 Column 100 Column 100
Pressure(kPa) 26.66 Pressure(kPa) 26.66 Pressure(kPa) 26.66
Condenser Temp (deg C) 86.23 Condenser Temp (deg C) 82.23 Condenser Temp (deg C) 73.20
Reboiler Temp (deg C) 97.09 Reboiler Temp (deg C) 96.95 Reboiler Temp (deg C) 96.48
Comp Recovery of Toluene 0.9999 Comp Recovery of Toluene 0.9999 Comp Recovery of Toluene 0.9999
Reflux Ratio 3 Reflux Ratio 5 Reflux Ratio 10
Total Trays w/o C & R 67 Total Trays w/o C & R 67 Total Trays w/o C & R 67
Tray Position 50 Tray Position 50 Tray Position 50
Composition of Exiting streams Composition of Exiting streams Composition of Exiting streams
Chemicals Overhead exiting Bottoms Exiting Chemicals Overhead exiting Bottoms Exiting Chemicals Overhead exiting Bottoms Exiting
Methane 0.0000 0.0000 Methane 0.0000 0.0000 Methane 0.0000 0.0000
Ethane 0.0698 0.0000 Ethane 0.0931 0.0000 Ethane 0.1510 0.0000
n-Hexane 0.0022 0.0000 n-Hexane 0.0030 0.0000 n-Hexane 0.0049 0.0000
Ethyl Toluene(1M3-Ebenzene) 0.0000 0.0000 Ethyl Toluene(1M3-Ebenzene) 0.0000 0.0000 Ethyl Toluene(1M3-Ebenzene) 0.0000 0.0000
Toluene 0.1129 0.0000 Toluene 0.1508 0.0000 Toluene 0.2444 0.0000
Benzene 0.1118 0.0000 Benzene 0.1492 0.0000 Benzene 0.2419 0.0000
Ethyl Benzene 0.5757 0.3287 Ethyl Benzene 0.5909 0.3447 Ethyl Benzene 0.3429 0.3985
Hydrogen 0.0001 0.0000 Hydrogen 0.0001 0.0000 Hydrogen 0.0001 0.0000
Oxygen 0.0000 0.0000 Oxygen 0.0000 0.0000 Oxygen 0.0000 0.0000
Nitrogen 0.0023 0.0000 Nitrogen 0.0030 0.0000 Nitrogen 0.0049 0.0000
Water 0.0000 0.0000 Water 0.0000 0.0000 Water 0.0000 0.0000
Ethylene 0.0046 0.0000 Ethylene 0.0061 0.0000 Ethylene 0.0099 0.0000
Styrene 0.1207 0.6640 Styrene 0.0037 0.6486 Styrene 0.0000 0.5954
n-B-Benzene 0.0000 0.0000 n-B-Benzene 0.0000 0.0000 n-B-Benzene 0.0000 0.0000
Cumene 0.0000 0.0023 Cumene 0.0000 0.0021 Cumene 0.0000 0.0019
n-P-Benzene 0.0000 0.0026 n-P-Benzene 0.0000 0.0024 n-P-Benzene 0.0000 0.0022
AMS 0.0000 0.0023 AMS 0.0000 0.0021 AMS 0.0000 0.0019
Heating Duties Heating Duties Heating Duties
Condenser (kJ/h) 6.36911E+07 Condenser (kJ/h) 7.93204E+07 Condenser (kJ/h) 9.88086E+07
Reboiler (kJ/h) 1.04578E+08 Reboiler (kJ/h) 1.14809E+08 Reboiler (kJ/h) 1.28452E+08
Vessel Parameters Vessel Parameters Vessel Parameters
Vessel Reboiler Condenser Vessel Reboiler Condenser Vessel Reboiler Condenser
Diameter (m) 1.193 1.193 Diameter (m) 1.193 1.193 Diameter (m) 1.193 1.193
Height(m) 1.789 1.789 Height(m) 1.789 1.789 Height(m) 1.789 1.789
Volume(m
3
) 2.000 2.000 Volume(m
3
) 2.000 2.000 Volume(m
3
) 2.000 2.000
Liq Vol. (%) 50.000 50.000 Liq Vol. (%) 50.000 50.000 Liq Vol. (%) 50.000 50.000
Level Calculator Horizontal cylinder Horizontal cylinder Level Calculator Horizontal cylinder Horizontal cylinder Level Calculator Horizontal cylinder Horizontal cylinder
Fraction Calculator Use levels and nozzles Use levels and nozzles Fraction Calculator Use levels and nozzles Use levels and nozzles Fraction Calculator Use levels and nozzles Use levels and nozzles
Vessel Delta P (kPa) 0.00 0.00 Vessel Delta P (kPa) 0.00 0.00 Vessel Delta P (kPa) 0.00 0.00
Fixed Vessel P Spec. (kPa) 26.66 26.66 Fixed Vessel P Spec. (kPa) 26.66 26.66 Fixed Vessel P Spec. (kPa) 26.66 26.66
Tray Section Tray Section Tray Section
Diameter (m) 1.500 Diameter (m) 1.500 Diameter (m) 1.500
Tray/Packed Space (m) 0.550 Tray/Packed Space (m) 0.550 Tray/Packed Space (m) 0.550
Tray/Packed Vol.(m
3
) 0.972 Tray/Packed Vol.(m
3
3
) 0.972
Hold up (m
3
) 0.088 Hold up (m
3
) 0.088 Hold up (m
3
) 0.088
C.7: Optimization Reflux Ratio (2of 6)
Figure 1A: Optimization of Reflux Ratio
Comp Recovery of Toluene = 0.9999
0.0E+00
2.0E+07
4.0E+07
6.0E+07
8.0E+07
1.0E+08
1.2E+08
3 5 10 15
Reflux Ratio
C
o
n
d
e
n
s
e
r

D
u
t
y

(
k
J
/
h
)
Figure 1B: Optimization of Reflux Ratio
Comp Recovery of Toluene =0.9999
0.0E+00
2.0E+07
4.0E+07
6.0E+07
8.0E+07
1.0E+08
1.2E+08
1.4E+08
1.6E+08
3 5 10 15
Reflux Ratio
R
e
b
o
i
l
e
r

D
u
t
y

(
k
J
/
h
)
Figure1C: Optimization of Reflux Ratio
0.0000
0.0200
0.0400
0.0600
0.0800
0.1000
0.1200
0.1400
0 2 4 6 8 10 12 14 16
Reflux Ratio
M
o
l
e

F
r
a
c
t
i
o
n

o
f

S
t
y
r
e
n
e

i
n

t
h
e

o
v
e
r
h
e
a
d
Figure1D: Optimization of Reflux Ratio
0.5700
0.5800
0.5900
0.6000
0.6100
0.6200
0.6300
0.6400
0.6500
0.6600
0.6700
0 2 4 6 8 10 12 14 16
Reflux Ratio
M
o
l
e

F
r
a
c
t
i
o
n

o
f

S
t
y
r
e
n
e

i
n

t
h
e

b
o
t
t
o
m
s
The amount of toluene recovered is not a specification in this optimization due to the degrees of freedom restriction on the distillation columns
Minimum Reflux From HYSYS Shortcut Calculation
Comp Recovery of Ethylbenzene 0.9999 Comp Recovery of Ethylbenzene 0.9999 Comp Recovery of Ethylbenzene 0.9999
AMS 0.0000 0.0018 AMS 0.0000 0.0018 AMS 0.0000 0.0019
Volume(m
3
) 2.000 2.000 Volume(m
3
) 2.000 2.000 Volume(m
3
) 2.000 2.000
Fraction Calculator Use levels and nozzles Use levels and nozzles Fraction Calculator Use levels and nozzles Use levels and nozzles Fraction Calculator Use levels and nozzles Use levels and nozzles
Tray/Packed Vol.(m
3
3
3
) 0.972
Hold up (m
3
) 0.088 Hold up (m
3
) 0.088 Hold up (m
3
) 0.088
Column 100
Optimal Reflux
Pressure(kPa) 26.66
Condenser Temp (deg C) 51.90
Reboiler Temp (deg C) 96.27
Comp Recovery of Ethylbenzene 0.9999
Reflux Ratio 12
Total Trays w/o C & R 67
Tray Position 50
Composition of Exiting streams
Chemicals Overhead exiting Bottoms Exiting
Methane 0.0000 0.0000
Ethane 0.2298 0.0000
n-Hexane 0.0074 0.0000
Ethyl Toluene(1M3-Ebenzene) 0.0000 0.0000
Toluene 0.3715 0.0000
Benzene 0.3681 0.0000
Ethyl Benzene 0.0005 0.4248
Hydrogen 0.0002 0.0000
Oxygen 0.0000 0.0000
Nitrogen 0.0075 0.0000
Water 0.0000 0.0000
Ethylene 0.0151 0.0000
Styrene 0.0000 0.5693
n-B-Benzene 0.0000 0.0000
Cumene 0.0000 0.0019
n-P-Benzene 0.0000 0.0021
AMS 0.0000 0.0019
Heating Duties
Condenser (kJ/h) 7.21977E+07
Reboiler (kJ/h) 9.84124E+07
Vessel Parameters
Vessel Reboiler Condenser
Diameter (m) 1.193 1.193
Height(m) 1.789 1.789
Volume(m
3
) 2.000 2.000
Liq Vol. (%) 50.000 50.000
Level Calculator Horizontal cylinder Horizontal cylinder
Fraction Calculator Use levels and nozzles Use levels and nozzles
Vessel Delta P (kPa) 0.00 0.00
Fixed Vessel P Spec. (kPa) 26.66 26.66
Tray Section
Diameter (m) 1.500
Tray/Packed Space (m) 0.550
Tray/Packed Vol.(m
3
) 0.972
Hold up (m
3
) 0.088
Comp Recovery of EB = 0.9999
0.00E+00
5.00E+07
1.00E+08
1.50E+08
2.00E+08
2.50E+08
3.00E+08
3.50E+08
3 5 10 12 15 20 30 40 50
Reflux Ratio
C
o
n
d
e
n
s
e
r

D
u
t
y

(
k
J
/
h
)
Figure 2B: Optimization of Reflux Ratio
Comp Recovery of EB =0.9999
0
10
20
30
40
50
60
3 5 10 12 15 20 30 40 50
Reflux Ratio
R
e
b
o
i
l
e
r

D
u
t
y

(
k
J
/
h
)
Figure 2C: Optimization of Reflux Ratio
Comp Recovery of EB =0.9999
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0 10 20 30 40 50 60
Reflux Ratio
M
o
l
e

F
r
a
c
t
i
o
n

o
f

S
t
y
r
e
n
e

i
n

t
h
e

o
v
e
r
h
e
a
d
Comp Recovery of Toluene = 0.9999
0.00E+00
2.00E+07
4.00E+07
6.00E+07
8.00E+07
1.00E+08
1.20E+08
3 5 10 15
Reflux Ratio
C
o
n
d
e
n
s
e
r

D
u
t
y

(
k
J
/
h
)
General Trends:
Reflux Ratio Solved by HYSYS
As the number of columns decreases the duty on the condenser and reboiler increases
As the number of columns decreases the mol fraction of ethyl benzene exiting in the distillate increases
As the number of columns decreases the purity of styrene increases because of the amount of ethyl benzene exiting in the distillate,
but there is a point where you start getting less purity of styrene.
AMS 0.0000 0.0019 AMS 0.0000 0.0019 AMS 0.0000 0.0019
Volume(m
3
) 2.000 2.000 Volume(m
3
) 2.000 2.000 Volume(m
3
) 2.000 2.000
Fraction Calculator Use levels and nozzles Use levels and nozzles Fraction Calculator Use levels and nozzlesUse levels and nozzles Fraction Calculator Use levels and nozzles Use levels and nozzles
Tray/Packed Vol.(m
3
3
3
) 0.972
Hold up (m
3
) 0.088 Hold up (m
3
) 0.088 Hold up (m
3
) 0.088
OPTIMAL STAGE FROM SHORT-CUT DIST. IN HYSYS
AMS 0.0000 0.0019 AMS 0.0000 0.0019 AMS 0.0000 0.0019
Volume(m
3
) 2.000 2.000 Volume(m
3
) 2.000 2.000 Volume(m
3
) 2.000 2.000
Fraction Calculator Use levels and nozzles Use levels and nozzles Fraction Calculator Use levels and nozzlesUse levels and nozzles Fraction Calculator Use levels and nozzles Use levels and nozzles
Tray/Packed Vol.(m
3
3
3
) 0.972
Hold up (m
3
) 0.088 Hold up (m
3
) 0.088 Hold up (m
3
) 0.088

Appendix D: Compressor Optimization
Compressors Total Cost/Year Compressors Total Cost/Year Compressors Total Cost/Year
1 135,211,913.38 $ 1 83,109,284.25 $ 1 16,723,672.81 $
2 46,301,845.84 $ 2 36,885,784.77 $ 2 13,259,425.74 $
3 36,120,548.92 $ 3 31,026,285.60 $ 3 12,954,054.50 $
4 34,700,489.93 $ 4 30,567,660.67 $ 4 12,974,991.53 $
5 34,117,414.99 $ 5 30,323,544.51 $ 5 13,112,584.04 $
6 34,019,360.00 $ 6 30,344,373.78 $ 6 13,270,201.88 $
7 34,056,600.61 $ 7 30,474,470.36 $ 7 13,343,714.61 $
1 14,393,491.14 $ 1 11,799,344.63 $ 1 11,552,286.13 $
2 11,988,687.07 $ 2 10,330,926.05 $ 2 10,271,294.13 $
3 11,738,395.62 $ 3 10,156,880.73 $ 3 10,070,266.22 $
4 11,816,536.09 $ 4 10,263,640.47 $ 4 10,211,462.87 $
5 11,976,656.42 $ 5 10,423,114.77 $ 5 10,394,355.66 $
6 12,141,798.15 $ 6 10,534,134.01 $ 6 10,482,010.82 $
7 12,181,480.61 $ 7 10,598,345.00 $ 7 10,562,234.00 $
1 9,993,175.16 $ 1 9,442,799.04 $ 1 8,645,010.91 $
2 9,272,843.40 $ 2 9,054,784.68 $ 2 8,584,023.83 $
3 9,079,644.47 $ 3 8,820,671.40 $ 3 8,343,378.82 $
4 9,266,368.96 $ 4 9,072,796.99 $ 4 8,654,569.23 $
5 9,465,635.45 $ 5 9,210,912.53 $ 5 8,748,205.56 $
6 9,515,501.58 $ 6 9,321,584.03 $ 6 8,897,823.72 $
7 9,613,541.49 $ 7 9,418,821.32 $ 7 8,968,179.58 $
1 442,471.46 $ 1 3,085,513.74 $ 1 11,254,434.85 $
2 453,857.44 $ 2 3,284,760.49 $ 2 10,294,761.84 $
3 454,264.96 $ 3 3,424,930.82 $ 3 10,194,445.14 $
4 471,742.91 $ 4 3,742,178.44 $ 4 10,546,200.01 $
5 10,949,864.13 $
Compressors Total Cost/Year Compressors Total Cost/Year
1 928,140.44 $ 1 4,124,658.09 $ Compressors Total Cost/Year
2 960,210.75 $ 2 4,081,197.03 $ 1 1,749,431.52 $
3 968,565.58 $ 3 4,144,069.67 $ 2 3,673,363.34 $
4 4,328,521.09 $
5 4,486,006.45 $
K-200
K-300
K-202
K-401 K-402 K-403
K-406
K-407 K-408 K-409
K-201
D.1: Compressor Optimization Analysis
K-404 K-405
K-410 K-400
D.2: K-404 Optimization Analysis
$11,500,000.00
$12,000,000.00
$12,500,000.00
$13,000,000.00
$13,500,000.00
$14,000,000.00
$14,500,000.00
$15,000,000.00
1 2 3 4 5 6 7
# Compressors
C
o
s
t

A
n
n
u
a
l
l
y
P
ad
7.904 10
6
W =
(10-65a) P
ad
G H
ad
:=
H
ad
4.882 10
4
Sv =
(10-64a) H
ad
k R
c
T
1
k 1
p
2
p
1
|
\
|
|
k 1 ( )
k
1
:=
R
c
8.314
J
mol K
\
|
|
1
M
W
:= k 1.1204 :=
M
W
G
M
:= G 5.8282 10
5
kg
hr
:=
p
1
135.78 10
3
Pa := p
2
263.38 10
3
Pa :=
T
1
273.15 86.93 + ( )K := T
2
273.15 122.03 + ( )K :=
M 13841 10
3
mol
hr
:=
(10-67)
( ) k k
p
p
T T
/ 1
1
2
1 2
|
|
\
|
=
Assume polytropic behavior that approaches adiabatic (Perry's page 10-37)
D.3: Compressor Hand Calculation Example

Appendix E: Heat Exchanger Design
Constants:
Density: n
p
2 := K
c
0.3 := S 0.5 :=
2.224
kg
m
3
:=
k
constant
0.000163
kg m
s
4
A
:=
Equations:
Ac D
i
2
:= G
M
t
Ac NP
:=
k 1 S ( )
2
K
c
+
0.5 n
p
1
( )
n
p
+ := Re
D
i
G
:= Pr
C
p

k
constant
:=
T
average
T
in
T
out
+
2
:= f 0.046 Re
.2
:=
T
1
T
otherin
T
average
:=
B 1
0.51 k n
p
T
1
w
|
\
|
|
0.28
T
out
T
in
( )
Pr
2
3
+ :=
1.02
w
|
\
|
|
0.14
:=
P
2 B f G
2
Length n
p
|
\
|
D
i

:=
P 80.234 Pa =
E.1: Example Pressure Drop Calculation (1 of 2)
Tube Side Pressure Estimation of E-1000
From "Plant Design and Economics for Chemical Engineers" Pg. 667
Tube Diameter: Mass Flow: Visocity (At Bulk and Wall):
D
i
.15 m := M
t
519200
kg
hr
:=
.00956 poise :=
Number of Tubes:
w
.01241 poise :=
NP 200 :=
Temp. In and Out:
Cp at Bulk Temp.:
T
in
28.2 273.15 + ( ) K :=
C
p
1.542 1000
J
kg C
:=
T
out
47.5 273.15 + ( ) K :=
T
otherin
60 273.15 + ( ) K :=
Length:
Length 6 m :=
P 5.542Pa =
P
4 f G
s
2
D
s
1 N
b
+
( )
2 D
e
w
|
\
|
|
0.14
:=
Re
D
e
G
s
:=
D
e
4 0.86 P
t
2
0.25 D
o
2

|
\
|
D
o
:=
N
b
L
s
L
b
t
b
+
1 :=
G
s
M
t
S
m
:= S
m
D
s
P
d
L
b
P
t
:=
Equations:
D
o
0.1 m :=
t
b
0.1 m :=
f 0.025 := P
t
0.2 m :=
L
s
6 m :=
L
b
3 m :=
P
d
0.1 m := D
s
2.5 m :=
w
.4251 poise := 1465
kg
m
3
:=
.41330 poise :=
M
t
1435000
kg
hr
:=
Known:
From "Plant Design and Economics for Chemical Engineers" Pg. 706-707
Shell Side Pressure Drop Estimation E-100 Coolant
E.1: Example Pressure Drop Calculation (2 of 2)
A 274.11 m
2
= A
q
U
he
T
lm
:=
U
he
425
W
m
2
K
:=
T
lm
5.832K = T
lm
Ts
in
Tw
o
( )
Ts
o
Tw
in
( )
ln
Ts
in
Tw
o
( )
Ts
o
Tw
in
( )
:=
Water and Styrene
q 6.794 10
5
W = q U
tank
A T :=
T 13.889 K = T Tair Ts
in
:=
A 2.576 10
3
m
2
= A D h
D
2
|
\
|
|
2
+ :=
D 20m := h 36m :=
U
tank
18.987
kg
s
3
K
= U
tank
1
1
h
air
x
steel
k
steel
+
1
h
s
+
:=
Air and Styrene
x
steel
0.075m :=
k
steel
45
W m
m
2
K
:= h
s
1000
W
m
2
K
:= h
air
20
W
m
2
K
:=
Tair 273.15 37.77778 + ( )K :=
Ts
o
273.15 18.3333 + ( )K := Ts
in
273.15 23.88889 + ( )K :=
Tw
o
293.15K := Tw
in
283.15K :=
E.2: Styrene Tank Heat Exchanger Size

Appendix F: Reactor Sizing
F.1: Dehydrogenation Reactor Size
Time 8000 hr :=
GHSV 225 hr
1
:=
Molar_Flow 19158000
mole
hr
:=
Vol_Flow
Molar_Flow
48.281
mole
m
3
:= Vol_Flow 110.223
m
3
s
=
Vol
Vol_Flow
GHSV
:=
Vol 1.764 10
3
m
3
=
Num
reactors
4 :=
Vol
reactor
Vol
Num
reactors
:=
Vol
reactor
440.891 m
3
=

Appendix G: Economic Optimization
Direct Costs
Purchased Equipment Costs: $384.6
Delivery Costs: $38.5
Installation Costs: $198.8
Instrumentation & Controls: $152.3
Piping: $287.7
Electrical Systems: $46.5
Buildings: $76.2
Yard Improvements: $42.3
Service Facilities: $296.1
Total Direct Costs: $1,523.0
Total Direct Costs:
Indirect Costs
Engineering and Supervision: $139.6
Construction Expenses: $173.5
Legal Expenses: $16.9
Contractor's Fee: $93.1
Contingency: $186.1
Total Indirect Costs: $609.2
Total Indirect Costs:
FIXED CAPITAL INVESTMENT
Working Capital
Working Capital: $376.5
Total Working Capital: $376.5
TOTAL CAPITAL INVESTMENT
G.1: Investment Summary
Styrene Monomer Production Process
TOTAL
$1,523.0
$609.2
$2,508.7
$2,132.2
Raw Material Price Annual Amount Annual Cost of Raw Material
($/kg) (million kg/yr) (million $)
Ethane 0.34 317.07 108.1
Benzene 0.83 704.93 581.8
Air 0.45 9.43 4.2
Dehydrogenation Catalyst 115.00 0.24 27.8
Alkylation Catalyst 105.00 0.02 1.7
Transalkylation Catalyst 40.00 0.01 0.3
TBC (Inhibitor) 63.80 0.02 1.4
DNP (Inhibitor) 260.00 0.02 6.2
Total 731.5
Product Price Annual Amount Annual Value of Product
($/kg) (million kg/yr) (million $)
Styrene 2.17 898.11 1950.3
Toluene 0.76 34.01 25.9
Total 1976.2
Utility Price Annual Amount Annual Cost of Utility
(million $)
Electricity 7.54 /kWh 1.16E+09 87.7
Refrigeration (to -50C) 14 $/GJ 5.68E+06 79.5
Steam, Saturated
3550 kPa (243.38C) 8 $/1000kg 1.51E+06 12.1
150 kPa (109.95C) 2 $/1000kg 3.88E+05 0.8
Water Treatment 36 $/1000kg 3.05E+05 11.0
Cooling Water (15C) 8 /m
3
8.51E+07 6.8
Total 197.8
Raw Material, Product, & Utility Summary
G.2: Economic Summary (1 of 5)
Current Chemical Engineering Index (for 2006) = 493
Projected Chemical Engineering Index for 2007 = 519
Equipment Type Equipment Cost
(2007 MM$)
REACTOR VESSELS 6.447
DISTILLATION VESSELS 14.690
TRAY COSTS 2.411
HEAT EXCHANGERS 94.289
COMPRESSORS 189.822
PUMPS 0.115
TURBINES 69.590
STORAGE TANKS 9.644
TOTAL 387.008
Purchased Equipment Cost Summary
Raw Materials
Benzene
Ethane
Air
Dehydogenation Catalyst
Alkylation Catalyst
Transalkyation Catalyst
TBC (Inhibitor)
DNP (Inhibitor)
Total Raw Materials:
Utilties
Waste Treatment
General Expenses
Operating Labor
Operating Supervision
Maintainance/Repairs
Operating Supplies
Laboratory Charges
Total Byproducts:
TOTAL
Variable Cost Summary
TOTAL
$0.294 per lb of Styrene $581.8
Styrene Production Process
Per lb Styrene
$0.055 per lb of Styrene
$197.8
$731.5
$0.078 per lb of Styrene $154.6 $154.6
$0.547 per lb of Styrene $1,084.0 $1,084.0
$27.8
$4.2
$108.1
$79.5
$6.2
$1.4
$0.3
$1.7
$11.0
High Pressure Steam
Low Pressure Steam
Cooling Water
Refrigeration
Electricity
Total Utilities:
Fixed Charges
Property Taxes $43.8
Insurance $21.9
Total Fixed Charges: $65.7
Plant Overhead
General Plant Overhead $80.7
Total Plant Overhead: $80.7
General Expense
Administration $26.9
Distribution/Selling $69.1
Research & Development $55.3
Total General Expense: $151.3
TOTAL
TOTAL
$65.7
Fixed Cost Summary
$80.7
$151.3
$297.7
Year
Percentage
of Design
Capacity
Sales Capital Costs Working Capital Variable Costs Fixed Costs
Depreciation
Allowance
(MACRES)
Taxable Income
Income Tax
Costs
Net Earnings
Annual Cash
Flow
Cumulative Net
Present Value at
15.0%
2007 0.0% Construction -$319.8 -$319.8 -$319.8
2008 0.0% Construction -$746.3 -$746.3 -$968.8
2009 0.0% Construction -$1,066.1 -$376.5 -$1,442.6 -$2,059.6
2010 45.0% $988.1 -$542.0 -$148.8 -426.4 $0.0 $0.0 $297.3 $297.3 -$1,864.1
2011 90.0% $1,976.2 -$1,084.0 -$297.7 -682.3 $0.0 $0.0 $594.6 $594.6 -$1,524.2
2012 90.0% $1,976.2 -$1,084.0 -$297.7 -409.4 $185.2 -$64.8 $529.7 $529.7 -$1,260.8
2013 90.0% $1,976.2 -$1,084.0 -$297.7 -245.2 $349.3 -$122.3 $472.3 $472.3 -$1,056.6
2014 90.0% $1,976.2 -$1,084.0 -$297.7 -245.2 $349.3 -$122.3 $472.3 $472.3 -$879.1
2015 90.0% $1,976.2 -$1,084.0 -$297.7 -123.7 $470.9 -$164.8 $429.7 $429.7 -$738.6
2016 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$628.7
2017 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$533.2
2018 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$450.2
2019 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$377.9
2020 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$315.1
2021 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$260.5
2022 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$213.0
2023 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$171.7
2024 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$135.8
2025 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$104.6
2026 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$77.4
2027 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$53.8
2028 90.0% $1,976.2 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $386.5 -$33.3
2029 90.0% $1,976.2 $376.5 -$1,084.0 -$297.7 $594.6 -$208.1 $386.5 $763.0 $2.0
**All numbers are in millions of dollars
Cash Flow Summary
**All numbers are in millions of dollars
The Investor's Rate of Return (IRR) for this Project is: 15.0%
The Net Present Value (NPV) at 15% for this Project is: $1.99
ROI Analysis (Seventh Production Year)
Annual Sales:
Annual Costs:
Depreciation:
Income Tax:
Net Earnings:
Total Capital Investment:
ROI:
G.3: Profitability Measures
$1,976.2
-$1,381.7
15.40%
$0.0
-$208.1
$386.5
$2,508.7
Product Prices
Product Prices ($/lb) $0.75 $0.80 $0.85 $0.90 $0.95 $0.99 $1.05 $1.10 $1.15 $1.20 $1.25 $1.30 $1.35
Product Prices ($/kg) $1.65 $1.76 $1.87 $1.98 $2.09 $2.17 $2.31 $2.43 $2.54 $2.65 $2.76 $2.87 $2.98
IRR -0.8% 3.6% 7.2% 10.4% 13.2% 15.0% 18.2% 20.4% 22.4% 24.2% 26.1% 27.8% 29.5%
G.4: IRR Analysis - Product Price Fluctuation
IRR Analysis - Product Price Fluctuation
-5.0%
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
30.0%
35.0%
$0.70 $0.80 $0.90 $1.00 $1.10 $1.20 $1.30 $1.40
Styrene Monomer Product Price ($/lb)
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Senior Design Final Report

Professor J.A. Sykes

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