KUWAIT UNIVERSTY
COLLEGE OF ENGINEERING & PETROLEUM
CHEMICAL ENGINEERING DEPARTMENT
Hysys Report (Group2)
Production of Ethylbenzene
Done by:
Mohammed Al-Mohsen
204114376
Yaqoub Bader Ali
205216198
Mohammed Al-Faraj
204111522
Nasser Al-Ajmi
205114238
Ali Shamsaldein
204113616
Supervised By:
Prof. M. A. Fahim
Eng. Yusuf Ismail
Abstract:
A computer simulation of Ethylbenzene plant is described in this report,
the software used for this simulation is called Hysys. Various factor and
balance in the production of Ethylbenznene by liquid phase alkylation of
ethylene and benzene are estimated. The process of reaction section, pre
distillation section and distillation section have been described, also each
equipments used in the simulation have been reported individually in this
report.
2
Table of Contents
2 ............................................................................................................ Abstract
4 ...................................................................................................... List of Figure
6 ..........................................................................................................List of Tables
7 .......................................................................................................... Introduction
8 ................................................................................................ Problem statement
9 .......................................................................... Insertion of Components in Hysys
11 ........................................................................ Defending Fluid Package in Hysys
12 ................................................................................. Defining Reactions in Hysys
16 .............................................................................................. Process description
16 .................................................................................................. 1-Reaction section
17 ........................................................................................Hysys process description
19 ...................................................................... Equipments used in reaction section
35 ......................................................................................... 2- Pre distillation section
36 ........................................................................................Hysys process description
37 ...................................................................... Equipments used in reaction section
45 ................................................................................................ 3-Distillation section
46 ........................................................................................Hysys process description
47 ...................................................................... Equipments used in reaction section
54 .......................................................................................................... Conclusion:
55 ............................................................................................................ Appendix:
3
List of Figures
7...............................................................................................................................................Figure 1: Hysys3.2
9....................................................................................................................... Figure 2: Component List View
9.............................................................................................................. Figure 3: Simulation Basis Manager
10 ......................................................................................................... Figure 4: Tabular HypotheticalI Input
10 ........................................................................................................ Figure 5:UNIFAC Component Builder
11 ................................................................................................................. Figure 6: Fluid Package: Basis-1
12 ................................................................................................................. Figure 7: Fluid Package: Basis-1
13 .......................................................................................................................................... Figure 8: Reactions
13 ....................................................................................................... Figure 9: Conversion Reaction: Rxn-1
14 ..................................................................................................... Figure 10: conversion Reaction: Rxn-1
14 ........................................................................................................... Figure 11: Simulation Basis Manger
15 ...................................................................................................................... Figure 12: Reaction Set:Set-1
16 ......................................................................................................... Figure 13: Reaction section in Hysys
19 ........................................................................................................................... Figure 14: Splitter TEE-100
20 ........................................................................................................................... Figure 15: Splitter TEE-101
21 ................................................................................................................................ Figure 16:Mixer MIX-104
22 ................................................................................................................................ Figure 17:Mixer MIX-100
23 ............................................................................................................................... Figure 18: Mixer MIX-101
24 ................................................................................................................................ Figure 19:Mixer MIX-102
25 ................................................................................................................................ Figure 20:Mixer MIX-103
26 ............................................................................................................................... Figure 21: Mixer MIX-105
27 ............................................................................................................................... Figure 22: Mixer MIX-106
28 ................................................................................................................................. Figure 23: Cooler E-100
29 ...................................................................................................................................Figure 24:Cooler E-101
30 .................................................................................................................. Figure 25: Reactor RA-STAGE1
31 .................................................................................................................. Figure 26: Reactor RA-STAGE2
32 .................................................................................................................. Figure 27: Reactor RA-STAGE3
33 .................................................................................................................. Figure 28: Reactor RA-STAGE4
34 ................................................................................................................ Figure 29:Reactor RTA-STAGE1
35 ................................................................................................ Figure 30:Pre distillation section in Hysys
37 ............................................................................................................... Figure 31: Heat Exchanger E-103
38 ................................................................................................................................. Figure 32: Heater E-102
39 ...................................................................................................................... Figure 33: Compressor K-101
40 ...................................................................................................................................Figure 34:Cooler E-108
41 ........................................................................................................................ Figure 35: Flash Drum V-100
42 ................................................................................................................................ Figure 36:Mixer MIX-107
43 ................................................................................................................................. Figure 37: Heater E-104
4
44 .............................................................................................................................. Figure 38:Scrubber T-100
45 ........................................................................................................Figure 39:Distillation section in Hysys
47 ............................................................................................................. Figure 40: Benzene Column T-102
48 .................................................................................................. Figure 41: Ethylbenzene column (T-102)
49 ............................................................................................Figure 42: Polyethylbenzene Column T-103
50 ................................................................................................................................. Figure 43: Cooler E-107
51 .................................................................................................................................. Figure 44: E-105 heater
52 ................................................................................................................................. Figure 45: E-106 Cooler
53 ...................................................................................................................... Figure 46: K-100 Compressor
5
List of Tables
19 ............................................................................................... Table 1: TEE-100 streams mass flow rate
20 ............................................................................................... Table 2: TEE-101 streams mass flow rate
21 ................................................................................................ Table 3: MIX-104 streams mass flow rate
22 ................................................................................................ Table 4: MIX-100 streams mass flow rate
23 .................................................................................... Table 5: Mixer MIX-101 streams mass flow rate
24 ................................................................................................ Table 6: MIX-102 streams mass flow rate
25 ................................................................................................ Table 7: MIX-103 streams mass flow rate
26 ................................................................................................ Table 8: MIX-105 streams mass flow rate
27 ................................................................................................ Table 9: MIX-106 streams mass flow rate
28 .................................................................................................... Table10: E-100 streams mass flow rate
29 ................................................................................................... Table 11: E-101 streams mass flow rate
30 ..................................................................................... Table 12: RA-STAGE1 streams mass flow rate
31 ..................................................................................... Table 13: RA-STAGE2 streams mass flow rate
32 ..................................................................................... Table 14: RA-STAGE3 streams mass flow rate
33 ..................................................................................... Table 15: RA-STAGE4 streams mass flow rate
34 ................................................................................... Table 16: RTA-STAGE1 streams Mass flow rate
38 ................................................................................................... Table 17: E-103 streams mass flow rate
39 ................................................................................................... Table 18: E-102 streams mass flow rate
40 ..................................................................................................... Table 19:K-101streams mass flow rate
41 ................................................................................................... Table 20: E-108 streams mass flow rate
42 ................................................................................................... Table 21: V-100 streams mass flow rate
43 .............................................................................................. Table 22: MIX-107 streams mass flow rate
44 ................................................................................................... Table 23: E-104 streams mass flow rate
45 ................................................................................................... Table 24: T-100 streams mass flow rate
48 ................................................................................................... Table 25: T-102 streams mass flow rate
49 ................................................................................................... Table 26: T-102 streams mass flow rate
50 ................................................................................................... Table 27: T-103 streams mass flow rate
51 ................................................................................................... Table 28: E-107 streams mass flow rate
52 ................................................................................................... Table 29: E-105 streams mass flow rate
53 ................................................................................................... Table 30: E-106 streams mass flow rate
54 ................................................................................................... Table 31: K-100 streams mass flow rate
6
Introduction:
In this project computerized simulation software is used to simulate the
processes of producing Ethylbenzene by liquid phase alkylation of benzene
with ethylene.
There are more than one simulation software used to
generating process flow diagram (PFD) and estimation the physical
properties, heat and materials balances, and simulate chemical engineering
equipment. In this project software called Hysys created by Hyprotech is used
for the simulation.
Figure 1: Hysys3.2
Hysys is a user-friendly computer software package developed by
Hyprotech.
The
package
combines
comprehensive
data
regression,
thermodynamic database access (TRC, DIPPR, DDB, API, PDS) and the
Mayflower distillation technology to enable the design and analysis of
separation systems, including azeotropic and extractive distillation and nonideal, heterogeneous and multiple liquid phase systems.
7
Problem statement:
Production of Ethylbenzene from Benzene and Ethylene by LiquidPhase Alkylation Using Zeolite Catalyst.
Composition and Flow rates of Raw Materials
1. Benzene
a. Benzene
108,999 lb/hr
b. Water
55 lb/hr
2. Ethylene
a. Light Paraffins
39 lb/hr
b. Ethylene
39,246 lb/hr
Reactions
C6H6 + C2H6 → C6H5CH2CH3
C6H6 + n C2H4 → C6H5(CH2CH3)n
Final Product Stream
Ethylbenzene
Composition & Flowrates
148 lb/hr
145,685 lb/hr (1,150 LB/YR at 0.9 stream
a. Benzene
b. Ethylbenzene
factor)
30 lb/hr
c. Xylenes
2 lb/hr
d. Polyethylbenzene
8
Insertion of Components in Hysys:
The simulation starts from Simulation basis manager bottom found on
the top bar. From component tab, components used within the process should
be included in the component list as the following.
Figure 2: Component List View
Not all of the components exist in the component library. Therefore,
Hypothetical component tab is used for insertion of some properties of the
component that’s not included.
From the hypothetical tab, new group is added with HypoGroup1 name.
Figure 3: Simulation Basis Manager
9
The component needed is sorted in the component class as
Hydrocarbon. In order to estimate the properties of the component Unifac is
used to build the structure of the component as the figure shown.
Figure 4: Tabular HypotheticalI Input
In the next figure, Unifac component structure is built by including the
sub groups and their numbers existing in the structure. Thereby, the
molecular weight of the component and other calculated critical properties are
assigned. For example, PolyEthylBenzene contains five of ACH group, one
ACCH2 group, two CH2 group and a single CH3 group.
Figure 5:UNIFAC Component Builder
The same procedures are done with Heavy components.
10
Defending Fluid Package in Hysys:
And then for the next tab, which is fluid package tab, from the view
bottom in current fluid packages list, Peng Robinson fluid packed is used.
Figure 6: Fluid Package: Basis-1
Fluid package is necessary to estimate the properties of the
components during the simulation. In the following step, all the reactions
included within the process must be defined. Reactions defined include main
reactions and side reactions. The two main reactions used within the process
are the alkylation and the transkylation reactions.
11
Defining Reactions in Hysys:
The following reactions are the set of reactions occurring within the two
reactors.
Alkylation reaction:
C6H6 C2H4 C6H5(C2H5)
Trans-Alkylation:

C6 H 6  C6 H 5 (C2 H 5 ) 2  2C6 H 5 (C2 H 5 )
Side reaction:
C6 H 5 (C2 H 5 )  C2 H 4 C6 H 5 (C2 H 5 ) 2

C6H6 10C2H4 C6H5(C2H5)10
C6H5 (C2H5 )  2H2O C6H6  CH4  CO2  2H2
 reactions can be divided into two sets; one set contains
The previous

the reactions
occurring in the alkylation reactor and for the another set, the
reactions occurring into the transkylation reactor.
Firstly, the whole reactions occurring within the process should be
added. From the reactions tab, in the reactions section , Add Rxn is selected.
Figure 7: Fluid Package: Basis-1
12
In the following window shown, the reaction type is specified,
Figure 8: Reactions
As it's known for the main Alkylation reaction is a conversion reaction.
Figure 9: Conversion Reaction: Rxn-1
Afterwards, as shown in the above figure, the components of the main
reaction are specified with their stoichiometric coeffients. It's noticeable the
coeffitients vary between the (-) and (+) signs. The minus sign indicates that
the component is a reactant (is being consumed) and The positive sign
consequently indicates that the component is a product ( is being generated).
13
In this next step, the base component is specified and the conversion
percent (%) is set in the Co cell.
Figure 10: conversion Reaction: Rxn-1
The reaction is ready.
The same way as the previous, the rest four reactions are added.
Defining reaction sets:
What follows is to sort the reactions added into two sets as mentioned before.
In the main reaction tab, in the reaction sets section, add set is selected.
Figure 11: Simulation Basis Manger
14
Next, as shown in the following figure, rxn1 , rxn2 , rxn3 and rxn5 are selected
in the active list.
Figure 12: Reaction Set:Set-1
Applying the same thing for set2 (transkylation reaction) but with
selecting rxn5 in the active list.
15
Process description:
1-Reaction section:
This section is responsible for the alkylation reaction of the benzene
and ethylene to produce Ethylbenzene and for the trans-alkylation reaction of
Polyethylbenzene with benzene to produce more Ethylbenzene.
Figure 13: Reaction section in Hysys
16
Hysys process description:
Ethylene is fed to the TEE-100 at 25 °C and 515 psig. Where ethylene
is divided into four streams with different ratio, first stream E1 with flow ratio of
0.236, second stream E2 with flow ratio of 0.215, third stream E3 with flow
ratio of 0.225, fourth stream with flow ratio of 0.324.
BENZENE REC (6) at 263 °C and 510 psig is divided in two streams by
TEE-101, the first stream BENZENE-REC(RA) is fed to the first bed of the
alkylation reactor, and the second stream BENZENE-REC(RTA) at 263 c and
510 psig is fed to the trans alkylation reactor, these two streams are mixed in
mixer (MIX-104).
Stream BENZENE-REC(RA) which contains an excess amount of
benzene is recycled from the effluent of T-101 at 263°C and 510 psig then
mixed with stream E4 in a mixer MIX-100, where the effluent RA-FEED from
the mixer is fed to the first bed of the alkylation reactor RA-STAGE1 at 250°C
and 510 psig. The rector effluents RA1-L and RA1-V that contains
Ethylbenzene as a product of the alkylation reaction between benzene and
ethylene are fed to a mixer MIX-101, the effluent from the mixer is cooled to
250 °C by cooler E101, so that liquid phase is maintained and to keep the
temperature from the last bed at 270°C. Stream RA1-M (2) at 250°C and 502
psig is fed to the second bed of reactor RA-STAGE2 with stream E3. The
effluent from the reactor mixed by mixer MIX-102 then cooled to 250°C by a
cooler E-100. The effluent stream RA2-M(2) at 250°C and 495 psig with
stream E2 at 25°C and 515 psig are fed to the third bed reactor. The reactor
effluent mixed by mixer MIX-103 with an excess amount of Ethylbenzene.
Stream RA3-M at 261°C and 487 psig with stream E1 at 25°C and 515 psig
are fed to the last stage of the alkylation reactor. The reactor effluent RA-LP is
in vapor phase and contains light paraffin, and stream RA-PRODUCT is in
liquid phase and contains an excess amount of ethylbenzene.
17
Stream RTA-FEED at 251.7°C and 510 psig is fed to the
Transalkylation reactor RTA-STAGE1 to produce more Ethylbenzene. The
reactor effluent mixed in mixer MIX-105 to produced stream RTA-PRODUCT
which contain ethylbenzene. Streams RTA-PRODUCT and RT-PRODUCT
are mixed in mixer MIX-106 to produced stream RA-RTA(1) at 267.9°C and
480 psig then fed to E-103 heat exchanger.
18
Equipments used in reaction section:
Splitter TEE-100:
Figure 14: Splitter TEE-100
Defined variable:
-
E1 split = 0.236
-
E2 split = 0.215
-
E3 split = 0.225
-
E4 split = 0.424
Calculated variable:
Table 1: TEE-100 streams mass flow rate
Stream name
Flow rate (Ib/hr)
E1
9283
E2
8457
E3
8850
E4
12744
19
Splitter TEE-101:
Figure 15: Splitter TEE-101
Defined variable:
-
None
Calculated variable:
Table 2: TEE-101 streams mass flow rate
Stream name
Flow rate (Ib/hr)
BENZENE-REC(6)
8.414E5
BENZENE-REC(RTA)
5.082E4
BENZENE-REC(RA)
7.905E5
20
Mixer MIX-104:
Figure 16:Mixer MIX-104
Defined variable:
-
None
Calculated variable:
Table 3: MIX-104 streams mass flow rate
Stream name
Flow rate (Ib/hr)
POLY-REC(5)
7223
BENZENE-REC(RTA)
5.082E4
RTA-FEED
5.804E4
21
Mixer MIX-100:
Figure 17:Mixer MIX-100
Defined variable:
-
None
Calculated variable:
Table 4: MIX-100 streams mass flow rate
Stream name
Flow rate (Ib/hr)
E4
1.274E4
BENZENE-REC(RA)
7.9032E4
RA-FEED
8.033E5
22
Mixer MIX-101:
Figure 18: Mixer MIX-101
Defined variable:
-
None
Calculated variable:
Table 5: Mixer MIX-101 streams mass flow rate
Stream name
Flow rate (Ib/hr)
RA1-V
2.078E5
RA1-L
5.954E5
RA1-M(1)
8.033E5
23
Mixer MIX-102:
Figure 19:Mixer MIX-102
Defined variable:
-
None
Calculated variable:
Table 6: MIX-102 streams mass flow rate
Stream name
Flow rate (Ib/hr)
RA2-L
8.121E5
RA2-V
0
RA2-M(1)
8.121E5
24
Mixer MIX-103:
Figure 20:Mixer MIX-103
Defined variable:
-
None
Calculated variable:
Table 7: MIX-103 streams mass flow rate
Stream name
Flow rate (Ib/hr)
RA3-V
0
RA3-L
8.206E5
RA3-M
8.206E5
25
Mixer MIX-105:
Figure 21: Mixer MIX-105
Defined variable:
-
None
Calculated variable:
Table 8: MIX-105 streams mass flow rate
Stream name
Flow rate (Ib/hr)
RTA-V
0
RTA-L
5.804E4
RTA-PRODUCT
5.804E4
26
Mixer MIX-106:
Figure 22: Mixer MIX-106
Defined variable:
-
None
Calculated variable:
Table 9: MIX-106 streams mass flow rate
Stream name
Flow rate (Ib/hr)
RA-PRODUCT
7.718E5
RTA-PRODUCT
5.804E4
RA-RTA(1)
8.299E5
27
Cooler E-100:
Figure 23: Cooler E-100
Defined variable:
-
Delta pressure = 0 psig
-
Delta Temperature =11.6 °C
Calculated variable:
-
Q2 = 1.392E7 [KJ/hr]
Table10: E-100 streams mass flow rate
Stream name
Flow rate (Ib/hr)
RA2-M(1)
8.121E5
RA2-M(2)
8.121E5
28
Cooler E-101:
Figure 24:Cooler E-101
Defined variable:
-
Delta pressure = 0 psig
-
Delta Temperature =16.6 °C
Calculated variable:
-
Q1 =3.627E7 [KJ/hr]
Table 11: E-101 streams mass flow rate
Stream name
Flow rate (Ib/hr)
RA1-M(1)
8.033E5
RA1-M(2)
8.033E5
29
Reactor RA-STAGE1:
Figure 25: Reactor RA-STAGE1
Defined variable:
-
Delta pressure = 7.5 psig
-
Reaction set = Set-1
Calculated variable:
-
Operation pressure = 502 psig
-
Operation temperature = 266°C
-
Rise in temperature =16°C
Table 12: RA-STAGE1 streams mass flow rate
Stream name
Flow rate (Ib/hr)
RA-FEED
8.033E5
RA1-V
2.078E5
RA1-L
5.954E5
30
Reactor RA-STAGE2:
Figure 26: Reactor RA-STAGE2
Defined variable:
-
Delta pressure = 7.5 psig
-
Reaction set = Set-1
Calculated variable:
-
Operation pressure = 495 psig
-
Operation temperature = 261°C
Table 13: RA-STAGE2 streams mass flow rate
Stream name
Flow rate (Ib/hr)
RA1-M(2)
8.033E5
RA2-L
8.121E5
RA2-V
0
E3
8850
31
Reactor RA-STAGE3:
Figure 27: Reactor RA-STAGE3
Defined variable:
-
Delta pressure = 7.5 psig
-
Reaction set = Set-1
Calculated variable:
-
Operation pressure = 487 psig
-
Operation temperature = 261°C
Table 14: RA-STAGE3 streams mass flow rate
Stream name
Flow rate (Ib/hr)
RA2-M(2)
8.121E5
E2
8457
RA3-L
8.206E5
RA3-V
0
32
Reactor RA-STAGE4:
Figure 28: Reactor RA-STAGE4
Defined variable:
-
Delta pressure = 7.5 psig
-
Reaction set = Set-1
Calculated variable:
-
Operation pressure = 480 psig
-
Operation temperature = 269°C
Table 15: RA-STAGE4 streams mass flow rate
Stream name
Flow rate (Ib/hr)
RA3-M
8.206E5
E1
9283
RA-LP
5.806E4
RA-PRODUCT
7.718E5
33
Reactor RTA-STAGE1:
Figure 29:Reactor RTA-STAGE1
Defined variable:
-
Reaction set = Set-2
-
Delta pressure = 0 psig
Calculated variable:
Table 16: RTA-STAGE1 streams Mass flow rate
Stream name
Flow rate (Ib/hr)
RTA-FEED
5.804E4
RTA-V
5.804E4
RTA-L
0
34
2- Pre distillation section:
This section is responsible for preparing the fresh benzene and the
reaction effluents for the distillation section. It also responsible for preparing
the recycled stream from the distillation section before entering the reaction
section.
Figure 30:Pre distillation section in Hysys
35
Hysys process description:
Stream RA-RTA(1) at 268°C and 480 psig coming from MIX-106 is fed
to the heat exchanger E-103 to cooled from 268 C to 190 C and form stream
RA-RTA(2) by using stream BENZENE-REC(2) at 159°C and 85 psig. Then
the produced stream BENZENE-REC(3) is heated by heater E-102 to 263°C
at 85 psig to form BENZENE_REC (4) which is 100% vapor, then
BENZENE_REC (4) is compresses to 510 psig at 342°C by compressor K101 to form BENZENE_REC(5) which is cooled again by cooler E-108 to 263
C and became BENZENE-REC(6) which is in liquid phase to be send to the
reaction section.
Stream RA-RTA(2) at 190°C and 480psig is fed to the flash drum V100 and separated to VAPORE-LP at 180°C and 117 psig and RA-RTA-(3) at
180°C and 117 psig . The VAPORE-LP is mixed with RA-LP which comes
from RA-STAGE4 by a mixer MIX-107 to form stream MIX-LP at 208°C and
117psig.
The BENZENE FEED(1) at 25°C and 100 psig is heated to 165°C and
100 psig to form BENZENE FEED(2) .the BENZENE FEED(2) with the MIXLP stream are fed to the scrubber T-100 which separate benzene BENZENE
FEED(3) at 167°C and100psig, water WASTE WATER at 138°C and 100psig
and light paraffin’s VENT GAS at 138.4°C. The stream BENZENE FEED(3)
is mixed with RA-RTA-(3) at MIX-108 to form stream DISTELATION FEED1
at 171°C and 100psig .
36
Equipments used in pre distillation section:
Heat Exchanger E-103:
Figure 31: Heat Exchanger E-103
Defined variable:
-
Delta pressure = 0 psig
Calculated variable:
Table 17: E-103 streams mass flow rate
Stream name
Flow rate (Ib/hr)
BENZENE-REC(1)
841360
BENZENE-REC(2)
841360
RA-RTA(1)
829860
RA-RTA(2)
829860
37
Heater E-102:
Figure 32: Heater E-102
Defined variable:
-
Delta pressure = 0 psig
-
Delta Temperature = 103°C
Calculated variable:
-
Q3 = 1.16E8 [KJ/hr]
Table 18: E-102 streams mass flow rate
Stream name
Flow rate (Ib/hr)
BENZENE-REC(3)
841360
BENZENE-REC(4)
841360
38
Compressor K-101
Figure 33: Compressor K-101
Defined variable:
-
Delta pressure = 2930 kpa
Calculated variable:
-
Q4 = 4.381E7 [KJ/hr]
Table 19:K-101streams mass flow rate
Stream name
Flow rate (Ib/hr)
BENZENE-REC(4)
841360
BENZENE-REC(5)
841360
39
Cooler E-108:
Figure 34:Cooler E-108
Defined variable:
-
Delta pressure = 0 psig
-
Delta Temperature = -79°C
Calculated variable:
Table 20: E-108 streams mass flow rate
Stream name
Flow rate (Ib/hr)
BENZENE-REC(5)
841360
BENZENE-REC(6)
841360
40
Flash Drum V-100:
Figure 35: Flash Drum V-100
Defined variable:
-
Delta pressure Inlet = 2500 kPa
-
Delta pressure Vapor outlet = 0 kPa
Calculated variable:
Table 21: V-100 streams mass flow rate
Stream name
Flow rate (Ib/hr)
RA-RTA(2)
829860
VAPORE –LP
59092
RA-RTA(3)
770770
41
Mixer MIX-107:
Figure 36:Mixer MIX-107
Defined variable:
-
None
Calculated variable:
Table 22: MIX-107 streams mass flow rate
Stream name
Flow rate (Ib/hr)
VAPORE –LP
59092
RA-LP
58057
MIX-LP
117150
42
Heater E-104:
Figure 37: Heater E-104
Defined variable:
-
Delta Pressure = 0 psig
-
Delta Temperature = -79°C
Calculated variable:
-
Q 9 = 1.446E7 [KJ/hr]
Table 23: E-104 streams mass flow rate
Stream name
Flow rate (Ib/hr)
BENZENE FEED (1)
109050
BENZENE FEED (2)
109050
43
Scrubber T-100:
Figure 38:Scrubber T-100
Defined variable:
-
P cond = 104 psig
-
P n = 114 psig
-
Benzene recovery in BENZENE FEED (3) = 0.99
-
Distillate rate = 700 Ib/hr
Calculated variable:
-
Q10 = 2.185E7 [KJ/hr]
Table 24: T-100 streams mass flow rate
Stream name
Flow rate (Ib/hr)
BENZENE FEED (2)
109050
BENZENE FEED (3)
223890
WASTE WATER
700
44
VENT-GAS
1610
MIX-LP
117150
3-Distillation section:
This section is responsible for recycling the benzene and the
Polyethylbenzene to the reaction section and for separating and collecting the
Ethylbenzene as a final product.
Figure 39:Distillation section in Hysys
45
Hysys Process description:
Stream
DISTILATION-FEED1,
which
consists
of
Benzene,
Ethylbenzene, Polyethylbenzene and other components enter the Benzene
Column T-102 at 171°C and 100 psig. The over head product of the Benzene
Column primarily consist of benzene and some Ethylbenzene is recycled to
the reaction section as a BENZENE-REC(1) at 158°C and 85psig. The
bottoms product BOTTOMS1 is feed to the Ethylbenzene column T-102 at
231°C and 95 psig. The over head product of the Ethylbenzene column EBPRODUCT(1) recover almost 99% of the Ethylbenzene feed to the distillation.
The EB-PRODOCT(1)
is cooled from 215°C to 66°C to form EB
PRODUCT(2) using E-107 cooler. The bottoms product BOTTOMS2 is feed
to the Polyethylbenzene Column at 260°C and 75psig. The over head product
POLY-REC(1) consist primarily of Polyethylbenzene is recycled to the
reaction section at 245°C and 60 psig while the bottoms product (RESDUE) is
collected as a residue at 564C and 65psig. The POLY-REC(1) is heated to
251°C by E-105 to maintain vapor phase then compress from 60 psig to
510psig by K-100 compressor to form POLY-REC(3) which is cooled from
354°C to 127°C by E-106 to maintain liquid phase of the POLY-REC(4)
stream.
46
Equipments used in Distillation section:
Benzene Column T-102:
Figure 40: Benzene Column T-102
Defined variable:
-
Number of stages = 36 stages
-
P cond = 85 psig
-
P reb = 95 psig
-
Benzene mass flow rate at the overhead product 1.064E4 Ibmole/hr
-
Ethylbenzene mass flow rate at the overhead product 1.02E4 Ibmole/hr
Calculated variable:
-
Q11 = 1.898E8 [KJ/hr]
-
Q12 = 1.826E8 [KJ/hr]
47
Table 25: T-102 streams mass flow rate
Stream name
Flow rate (Ib/hr)
DSTILATION-FEED1
994663
BENZENE-REC(1)
153301
BOTTOMS1
841362
Ethylbenzene column T-102:
Figure 41: Ethylbenzene column (T-102)
Defined variable:
-
Number of stages = 26 stages
-
P cond = 70 psig
-
P reb = 75 psig
-
Reflux Ratio = 5
-
Ethylbenzene recovery in EB PRODUCT(1) = 0.99
Calculated variable:
-
Q13 = 1.116E8 [KJ/hr]
-
Q14 = 1.092E8 [KJ/hr]
48
Table 26: T-102 streams mass flow rate
Stream name
Flow rate (Ib/hr)
BOTTOMS1
841362
EB PRODUCT(1)
144560
BOTTOMS2
8740
Polyethylbenzene Column T-103:
Figure 42: Polyethylbenzene Column T-103
Defined variable:
-
Number of stages = 14 stages
-
P cond = 60 psig
-
P reb = 65 psig
-
Reflux Ratio = 5
-
Polyethylbenzene recovery in POLY-REC(1) = 0.99
Calculated variable:
-
Q15 = 5.44E6 [KJ/hr]
-
Q16 = 5.92E6 [KJ/hr]
49
Table 27: T-103 streams mass flow rate
Stream name
Flow rate (Ib/hr)
BOTTOMS2
8740
POLY-REC(1)
7230
RESIDUE
1509
Cooler E-107:
Figure 43: Cooler E-107
Defined variable:
-
Delta Pressure = 0 psig
-
Delta Temperature = -149°C
Calculated variable:
-
Q17 = 2.082E7 [KJ/hr]
Table 28: E-107 streams mass flow rate
Stream name
Flow rate (Ib/hr)
EB PRODUCT(1)
144560
EB PRODUCT(2)
144560
50
Heater E-105:
Figure 44: E-105 heater
Defined variable:
-
Delta Pressure = 0 psig
-
Delta Temperature = 6.8°C
Calculated variable:
-
Q8 = 9.071E5 [KJ/hr]
Table 29: E-105 streams mass flow rate
Stream name
Flow rate (Ib/hr)
POLY-REC(1)
7230
POLY-REC(2)
7230
51
Cooler E-106:
Figure 45: E-106 Cooler
Defined variable:
-
Delta Pressure = 0 psig
-
Delta Temperature -227= °C
Calculated variable:
-
Q6 = 1.964 [KJ/hr]
Table 30: E-106 streams mass flow rate
Stream name
Flow rate (Ib/hr)
POLY-REC(3)
7230
POLY-REC(4)
7230
52
Compressor K-100:
Figure 46: K-100 Compressor
Defined variable:
-
Delta Pressure = 3103 psig
Calculated variable:
-
Q7 = 1.393E5 [KJ/hr]
Table 31: K-100 streams mass flow rate
Stream name
Flow rate (Ib/hr)
POLY-REC(2)
7230
POLY-REC(3)
7230
53
Conclusion:
In this process, the amount of Ethylbenzene produced by Hysys
simulation is 144030 Ib/hr, comparing this value with the theoretical value
145685 Ib/hr from the problem statement, it is found that the error is 1.13%
which is considered very small.
Usage of Hysys was found to be so effective, time consuming and
gave an accurate value of results.
54
55