Kuwait University
Collage of Engineering & Petroleum
Chemical Engineering Department
Plant Design
CHE 491
Hysys Reprot
Name
Salem Alkanaimsh
Sabah Alfadly
Mohamed albanny
Amer alnajjdy
Bader alrashidi
I.D
204113544
204114602
203111153
204112953
203113633
1
 Abstract :
In our report, we used hysys to simulate propylene oxide production and
compare it with actual results .We will mention in details about all units we have
used like reactors, distillation columns, heat exchangers, and pumps. Each stream
which content materials and any recycled that important will be mentioned also
.In the final report, we mentioned the final desired products (PO & styrene).
2
Table of Contents
Abstract
Table of contents
List of Tables
List of Figures
What is Hysys?
How to simulate by using Hysys ?
Epoxidation Process By using Ethyl Benzene
Reactions involved in the process
Units involved in the process
Simulation of the ethyl benzene oxidation by Hysys Program
Simulation of the propylene epoxidation by Hysys Program
Simulation of Styrene production section
2
3
4
5
8
9
12
12
14
17
21
32
conclusion
37
3
List of Tables
Table 1: Stoichiometric table of oxidation
of Ethyl benzene
Table 2:Stoichiometric table of
expoxidation of ethyl benzene
hydroperoxide
Table3:Stoichiometric table of
acetophenone hydrogenation.
Table4:Stoichiometric table of MBA
dehydration
Table5 :Summary of reactors in the process
Table6 :Summary of columns in the
process
Table7:Summary of pumps in the process
Table8:Summary of heat exchangers in the
process
Table9:Summary of compressors &
expanders of the process
Table10:Difference between the final
product (PO) in real plant & in hysys
program
Table11:Difference between the final
product (Styrene) in real plant & in hysys
program
12
13
13
13
14
14
15
15
16
30
35
4
List of Figures
Fig1:Defining the components in the
process
Fig.2:Hypotheticals
Fig.3:Defining the fluid package used
Fig.4:Defining the reaction if exist in the
process
Fig.5:First reactor: Oxidation reaction
Fig.6:Second Reactor : Expoxidation
reaction
Fig.7:Third Reactor : Hydrogenation
reaction
Fig.8:Forth Reactor: Dehydration reaction
Fig.9:Simulation of the ethyl benzene
oxidation by Hysys Program
Fig.10:Reaction of EB in CRV-100 &
treating the vapor effluent in absorber T100
Fig.11:Connections T-100
Fig.12:Treating the gases of T-100
Fig.13:Recycling EB back to the start of
the process
Fig.14:Treating the liquid effluent of CRV100 & sent it to the next section
Fig.15:Simulation of the propylene
epoxidation by Hysys Program
Fig.16:Expoxidation reaction in CRV-101,
and recycling propylene produced from T101 and T-103 back to the reactor
Fig.17:Expoxidation reaction in CRV-101,
and recycling propylene produced from T101 and T-103 back to the reactor
Fig.18:Reactor CRV-101
Fig.19:Distillation Column T-101
Fig.20:Connections T-101
Fig.21:Monitor T-101
Fig.22:Work sheet T-101
Fig.23:Distillation Column T-102
8
8
9
9
10
10
10
10
16
16
17
17
18
18
20
20
21
22
22
22
23
23
23
5
Fig.24:Connections T-102
Fig.25:Monitor T-102
Fig.26:Work sheet T-102
Fig.27:Distillation Column T-103
Fig.28:Connections T-103
Fig.29:Monitor T-103
Fig.30:Work sheet T-103
Fig.31:Purification of the desired products
through out T-104 & preparation of
reactants for the final section
Fig.32:Distillation Column T-104
Fig.33:Connections T-104
Fig.34:Monitor T-104
Fig.35:Work sheet T-104
Fig.36:Distillation Column T-105
Fig.37:Connections T-105
Fig.38:Monitor T-105
Fig.39:Work sheet T-105
Fig.40:Finding the errors
Fig.41:Styrene production section
Fig.42:Dehydration reaction in CRV-100-2
Fig.43: Styrene separation part.
24
24
24
25
25
25
25
26
Fig.44: First three columns of the sections.
32
Fig.45: Last two columns of the sections.
33
fig:46:Hydrogenation reactor.
Fig.47:Finding the errors
27
27
27
28
28
28
29
29
30
31
31
32
34
35
6
 What is Hysys?
Hysys program is one of the simulation programs used by process engineers.
It is a powerful tool for chemical processes and oil refineries. It includes tools for
estimation material balances, energy balances, vapor- liquid equilbria, and simulation
a lot of chemical engineering equipments. The purpose of simulation is to improve
process design, studying plant optimization, and generating process flow diagram
(PFD). In addition to hysys program, there are a lot of simulators like ChemCad and
PRO.
The data required to run hysys simulator vary. The can be divided into two
categories: required data, and optional data. Required data include components data,
thermodynamics data, stream data, and unit operation data. While the optional data
include reaction data if exist in the process.
As we said, hysys program is a tool for simulation. There is variety of units
listed in the program. Flash units heat exchangers, distillation columns, absorbers,
mixers, splitters, pumps, compressors, valves, and expanders are example of those
units. The most important units in hysys are reactors, and hysys has: conversion
reactors, equilibrium reactors, Gibbs reactors, CSTR reactors, and plug- flow
reactors.
Hysys has a lot of thermodynamics method to estimate the properties of
streams in a process. A lot of Equations of States exist in the database of the program
like: Soave-Redlich Kwong (SRK), and Peng-Robinson (PR). Also, a lot of liquid
activity methods exist like: Margulas equation, Van Laar equation, Wilson equation,
and UNIQUAC equation.
As we said, one of the purposes to use hysys program is to generate PFD. A
process flow diagram is a simplified picturial representation of the flow of materials
through equipments to produce a final product. For a process engineer, it is a basic
tool for development of flow diagram. Also, it is necessary for preparation of material
balances. A PFD could contains stream numbers, all major equipments with item tag
numbers, temperatures and pressure of each vessel for each operation, exchanger
duty, pump capacity, and number of trays in towers.
7
 How to simulate by using hysys program?
Simulating By hysys goes in different steps:
1. Defining the components in the process.
2. Defining the fluid package.
3. Defining the reactions if exist in the process.
 Defining the components in the process :
Fig1:Defining the components in the process
First of all, before we start the simulation by hysys, all the components must be
included in the components list of the process. These components were taken from the
material balances. Most of the compounds in the process are found in the hysys are found
in the data base of the program.
Fig.2:Hypotheticals
Unfortunately, not all the compounds are found in the data base of the hysys.
Methyl Benzyl Alcohol (MBA) is the only compound which is not available in the data
base. There are several information required to define the compound. The normal boiling
point and molecular weight are required to define MBA.
 Defining the fluid package used:
8
Fig.3:Defining the fluid package used
After that we shall define the fluid package used in this process. The fluid
package used is to estimate the properties of the compounds. We have chosen PRSV as a
fluid package since it suitable for all the compounds in the process.
 Defining the reaction if exist in the process:
Fig.4:Defining the reaction if exist in the process
Then we defined the reactions in the process. There are several reactions in this
process. They can be divided into 4 steps. These are: oxidation of Ethyl Benzene,
expoxidation of Ethyl Benzyl Hydroperoxide to produce propylene oxide, Hydrogenation
of AcetoPhoneon into MBA, and finally dehydration of MBA to styrene. The reactants
and products of each reaction were defined. For each one, we specified the stoichemictry
coefficients. The coefficients were in negative signs for reactants, and positive sign for
products. In the next four figures, we specified the reactions involved in each reactor.
A. First reactor: Oxidation reaction :
9
Fig.5:First reactor: Oxidation reaction
B. Second Reactor : Expoxidation reaction :
Fig.6:Second Reactor : Expoxidation reaction
C. Third Reactor : Hydrogenation reaction:
Fig.7:Third Reactor : Hydrogenation reaction
D. Forth Reactor: Dehydration reaction:
Fig.8:Forth Reactor: Dehydration reaction
10
 Epoxidation Process By using Ethyl Benzene:
Our supervisor assigned to us one of the four industrial processes used to produce
propylene oxide (PO). Our process was indirect oxidation of ethyl benzene. In addition to
producing PO, styrene is produced also to increase the profits and to have better
economics conditions. Hysys program was used to simulate the process. We can divide
the whole process into three different sections, each with its own reactions. These
sections are:
1. Ethyl benzene oxidation.
2. Epoxidation of Ethyl benzene Hydroperoxide & Purification of PO.
3. Styrene Production.
 Reactions involved in the process:
There are several reactions occur in this process to convert the raw materials ( EB, air,
hydrogen) into our desired final products ( PO, styrene). These reactions are listed below:
1. The oxidation of Ethyl benzene:
In this reaction, ethyl benzene and air are reacted together to give ethyl benzene
Hydroperoxide. This reaction takes place in the first section. In addition to that reaction,
two side reactions are taking place. In this step, methyl benzene alcohol (MBA), and
acetophenone (ACP) are formed
Species
C6H5C2H3
O2
C6H5CH(CH3)OOH
N2
C6 H 5C2 H 3  O2  C6 H 5 CH CH 3 OOH
Symbol
Inlet Feed Rate
Change in Reactor
Ethyl Benzene
Oxygen
Ethyl Benzene
Hydroperoxide
Nitrogen
F (EB)o
F(O2)o
F(EBHP)o
-x1 F (EB)o
-x1 F (EB)o
+x1 F (EB)o
Effluent rate from
Reactor
F (EB)o(1-x1)
F(O2)o-x1 F (EB)o
F(EBHP)o+x1 F (EB)o
F(N2)o
-
F(N2)o
Table 1: Stoichiometric table of oxidation of Ethyl benzene
2. Expoxidation of Ethyl Benzene Hydroperoxide :
The reaction is the most important reaction in the process since it gives us our final
product; propylene oxide. In this reaction, ethyl benzene hydroperoxide reacted with
propylene to produce both of PO, and MBA. It takes place in the second section of the
plant.
11
CH 3CHCH 2  C6 H 5CH CH 3 OOH  CH 3CHOCH 2  C6 H 5CH CH 3 OH
Species
C6H5CH(CH3)OOH
CH3CHCH2
C3H8
CH3CHOCH2
C6H5CH(CH3)OH
Symbol
EBHP
Propylene
Propane
PO
MBA
Inlet Feed Rate
F(EBHP)o
F(CH3CHCH2)o
F(C3H8)o
F(PO)o
F(MBA)o
Change in Reactor
-x2 F (EBHP)o
-x2 F (EBHP)o
+x2 F (EBHP)o
+x2 F (EBHP)o
Effluent rate from Reactor
F(EBHP)o-x2 F (EBHP)o
F(CH3CHCH2)o-x2 F (EBHP)o
F(C3H8)o
F(PO)o+x2 F (EBHP)o
F(MBA)o+x2 F (EBHP)o
Table 2: Stoichiometric table of expoxidation of ethyl benzene hydroperoxide
3. Acetophenone Hydrogenation :
This reaction and the following one take place in the final section, which is styrene
production. In order to produce styrene, MBA should be in sufficient quantities to lead to
styrene (4th reaction). ACP is converted to MBA in this reaction to have a greater yield
and thus increasing the production of styrene.
C6 H 5 COCH 3  H 2  C6 H 5 CH CH 3 OH
Species
C6H5COCH3
H2
C6H5CH(CH3)OH
Symbol
ACP
Hydrogen
MBA
Inlet Feed Rate
F(ACP)o
F(H2)o
F(MBA)o
Change in Reactor
-x3 F (ACP)o
-x3 F (ACP)o
+x3 F (ACP)o
Effluent rate from Reactor
F(ACP)o-x3 F (ACP)o
F(H2)o-x3 F (ACP)o
F(MBA)o+x3 F (ACP)o
Table 3: Stoichiometric table of acetophenone hydrogenation.
4. MBA Dehydration:
This is the last reaction of the process. In this reaction, MBA especially from the pervious
reaction is consumed and converted to styrene.
Species
C6H5CH(CH3)OH
H2O
C6H5CHCH2
C6 H 5CH CH 3 OH  C6 H 5CHCH 2  H 2 O
Symbol
Inlet Feed Rate
Change in Reactor
MBA
F(MBA)o
-x4 F (MBA)o
Water
F(H2O)o
-x4 F (MBA)o
Styrene
F(Strene)o
+x4 F (MBA)o
Effluent rate from Reactor
F(MBA)o-x4 F (MBA)o
F(H2O)o-x4 F (MBA)o
F(Styrene)o+x4 F (MBA)o
Table 4: Stoichiometric table of MBA dehydration.
12
 Units involved in the process:
Several units are involved in this process. Reactors, columns, pumps, compressors, and
heat exchangers are examples of these units. Each category will be discussed briefly.
1. Reactors:
#
Symbol
Section
Reactions
1
CRV100
CRV101
Ethyl benzene
oxidation
Epoxidation of
Ethyl benzene
Hydroperoxide
Styrene
production
Styrene
Production
2
3
4
CRV100-2
CRV101-2
Opreating
Pressure (psi)
50
Conversion (%)
1st reaction
Operating
temperature (oC)
190
2nd reaction
115
320
99.9
4th reaction
120
20
100
3rd reaction
93
1215
90
3.5
Table 5: Summary of reactors in the process
2. Columns :
#
1
2
Symbol
T-100
T-101
Type
Absorber
Distillation Column
Section
1st
2nd
3
4
T-102
T-103
Distillation Column
Distillation Column
2nd
2nd
5
6
7
8
9
10
11
T-104
T-105
T-103-2
T-101-2
Additional dis.
2nd dis.
Add
Distillation Column
Distillation Column
Distillation Column
Distillation Column
Distillation Column
Distillation Column
Distillation Column
2nd
2nd
3rd
3rd
3rd
3rd
3rd
Function
Recover EB from reactor gases & recycle it back
Separates Propylene from PO, EB, MBA, & ACP.
Propylene is recycled to E- 107
Separates propylene &propane from PO & EB.
Separates propylene from propane.
Propylene is recycled to E-108.
Separates PO from EB, MBA, & ACP.
Separates EB from MBA & ACP.
Separates styrene from water
Separates Styrene from MBA & ACP
Separates Styrene from MBA.
Separates Styrene from H2O.
Separates Styrene from MBA.
Table 6: Summary of columns in the process
3. Pumps :
#
1
2
3
Symbol
P-100
P-101
P-102
Section
1st
1st
2nd
Power (hp)
249.8
95.51
90.28
Function
Increase pressure of EB Feed to CRV-100 & T-100
Increase pressure of EB recycled in 1st section
Increase pressure of EBHP fed to CRV-101
13
4
5
6
7
8
9
P-107
P-101-2
P-102-2
P-103
P-104
P-108
2nd
3rd
3rd
3rd
3rd
3rd
3.031
0.0053
21.43
21.54
21.51
12.43
Increase pressure of ACP & MBA fed to CRV-100-2
Increase pressure of ACP & MBA fed to CRV-101-2
Increase pressure of ACP & MBA fed to CRV-101-2
Increase pressure of ACP & MBA fed to CRV-101-2
Increase pressure of ACP & MBA fed to CRV-101-2
Increase Pressure of the feed to column 2nd dis.
Table 7: Summary of pumps in the process
4. Heat Exchangers:
#
Symbol
Section
T (F)
1
2
3
4
5
6
7
E-105
E-104
E-102
E-109
E-111
E-112
E-113
1st
1st
1st
2nd
2nd
2nd
3rd
26.77
72.92
30.60
148.7
107.4
31.56
285.7
8
9
10
11
12
13
14
15
16
17
18
E-100
E-101
E-103
E-106
E-116
E-117
E-110
E-104-2
E-101-2
E-114
E-115
1st
1st
1st
1st
1st
1st
2nd
3rd
3rd
3rd
3rd
-218.2
-81
-57.56
-46.74
-17.33
-208.9
-5.929
-25.2
-122.8
-578
-642.1
19
E-108
2nd
20
E-107
2nd
-18
21.91
-48.6
127.5
Function
Heaters
Increase Temperature of EB fed to T-100
Increase Temperature of liquid effluent of CRV-100
Increase Temperature of liquid effluent of CRV-100
Increase Temperature of stream fed to T-103
Increase Temperature of stream fed to T-105
Increase Temperature of stream fed to T-105
Increases Temperature of feed to 2nd dis.
Coolers
Decrease Temperature of vent gas
Decrease Temperature of vent gas
Help to recycle EB back to the start of process
Decrease Temperature of EB recycled to the start of process
Decrease Temperature of recycle vacuum
Decrease Temperature of recycle vacuum
Decrease Temperature of stream fed to T-104
Decrease Temperature of stream fed to T-103-2
Decrease Temperature of stream outlet from T-101-2
Decrease Temperature of hydrogen feed
Decrease Temperature of hydrogen feed
Heat Exchangers
Decrease Temperature of liquid effluent of CRV-101
Increase Temperature of recycled propylene
Decrease Temperature of liquid effluent of CRV-101
Increase Temperature of recycled propylene
Table 8: Summary of heat exchangers in the process.
5. Compressors & Expanders :
#
Symbol
Section
P (psi)
1
K-100
1st
35.3
Function
Compressors
Increase Pressure of air fed to CRV-100
14
2
3
3
4
5
6
K-101
K-105
K-103
K-104
K-100-2
K-101-2
1st
1st
2nd
2nd
3rd
3rd
10
K-102
2nd
2
57.69
305.3
307
185.3
300
-170
Increase Pressure of outlet of V-104
Increase pressure of vacuum recycle
Increase Pressure of propylene fed to CRV-101
Increase Pressure of stream fed to T-103
Increase Pressure of hydrogen fed to CRV-101-2
Increase Pressure of hydrogen fed to CRV-101-2
Expanders
Decrease Pressure of stream fed to T-101.
Table 9: Summary of compressors & expanders of the process.
15
 Simulation of the ethyl benzene oxidation by Hysys Program :
Fig.9:Simulation of the ethyl benzene oxidation by Hysys Program
This is the first section of our process. It can be subdivided into 4 parts:
1.
2.
3.
4.
Reaction of EB in CRV-100 & treating the vapor effluent in absorber T-100.
Treating the gases of T-100.
Recycling EB back to the start of the process.
Treating the liquid effluent of CRV-100 & send it to the next section.
 Reaction of EB in CRV-100 & treating the vapor effluent in absorber T-100:
Fig.10:Reaction of EB in CRV-100 & treating the vapor effluent in absorber T-100
Stream 2a which almost consist of ethyl benzene is fed to pump p-100 to raise its
pressure from 14.7 psi to 50 psi. It is divided, so that 90 of it, enters the reactor CRV-100,
and the remaining enters T -100. The air enters the reactor to 50 psi after passing a
compressor (K-100). The reactor is operated at 190C and 50 psi. The temperature of the
reactor is raised from 140 to 190 to increase the feed to it. After passing to E-105 to raise
the temperature from 25 to 40C, the vapor outlet from the reactor is fed with the 10% of
ethyl benzene to recover unreacted EB for recycling back to the reactor.
16
Fig.11:Connections T-100
 Treating the gases of T-100:
Fig.12:Treating the gases of T-100
The outlet gases (stream t) from absorber T-100 are vented out after passing two
cooler (E-100, E-101) and two flash separator (V-101, V-102) stream 5 is consist mainly
of nitrogen and oxygen.
 Recycling EB back to the start of the process:
17
Fig.13:Recycling EB back to the start of the process
The liquid outlets from both (V-101, V-102) and vapors from V-103 are mixed in
MIX-103). NaOH is introduced to the section with recycle EB from product separation
section to recycle EB back to the start of the process. Before recycling EB back, it is fed
to pump (p-101) to raise the pressure from 1 psi to 14.7 psi, and introduced to a cooler
(E-109) to reduce its temperature from 50 oC to 25oC. The vacuum stream which contains
EB is recycled back. In order to recycle it, it is introduced to a compressor and coolers to
reduces its temperature to 25C.
 Treating the liquid effluent of CRV-100 & sent it to the next section:
Fig.14:Treating the liquid effluent of CRV-100 & sent it to the next section
The liquid outlet from reactor CRV-100 passes through a valve (VLV-101) to
reduce the pressure to 160 mmHg. The reactor influent passes through a heater coler to
reduce its temperature to 80oC. After that it passes to a flash drum (V-103), and the outlet
liquid is introduced to a heater (E-102) to raise its temperature to 97oC. Then it
introduced to a flash drum (V-104), and the liquid product goes to the 2nd section.
18

Modification we made to face problems during simulation :
1) The operating temperature was increased (CRV -100) to 190 C to increase
the fed to the reactor.
2) The split ratio of the EB fed was increased to increase the fed to the
reactor (90% goes to CRV-100 and 10% goes to column -100).
3) The heater E-104 was introduced so that the temperature of the liquid
outlet from CRV-100 increase to 141 C after the temperature has drop in
valve (VLV-101).
4) The flash drum V-103 was cooled down to 80 C before passing heater (E102).
5) At the end of the section several modifications take place. The recycle
liquid stream passes through pump P-101 and cooler (E-106) to adjust its
temperature and pressure. The recycle stream was divided and part of it
was purged out. The recycle vapor stream passes through compressor k1051 and coolers (E-116, E-117) to adjust its temperature and pressure.
The recycle stream was divided and part of it was purged out.
19
 Simulation of the propylene epoxidation by Hysys Program :
Fig.15:Simulation of the propylene epoxidation by Hysys Program
This is the second section of our process. In this section, PO is produced and purified. To
do so, a reactor, and 5 distillation columns are needed. This section can be subdivided
into 2 parts:
1.
Expoxidation reaction in CRV-101, and recycling propylene produced
from T-101 and T-103 back to the reactor.
2.
Purification of the desired products through out T-104 & preparation of
reactants for the final section.
 Expoxidation reaction in CRV-101, and recycling propylene produced from T-101
and T-103 back to the reactor:
Fig.16:Expoxidation reaction in CRV-101, and recycling propylene produced from T-101 and T-103 back
to the reactor
20
This is the second section of propylene oxide plant. The stream from the previous
section goes to p-102 to raise its pressure from 1 psi to 320 psi. The reactor (CRV 101) is
operated at T= 115C and P=320 psi. The EBHP from the pervious section is mixed with
propylene in the expoxidation reactor to yield PO. The propylene fed to the reactor has 3
sources:
1.
Propylene Feed.
2.
Recycle from T-101 after passing through E-107.
3.
Recycle from T-103 after passing through E-108.
The total propylene fed to the reactor is introduced to a compressor (k-103) to
increase it pressure from 14.7 psi to 320 psi. The liquid reactor effluent goes to heat
exchanger E-108 to reduce its temperature to 105oC by using recycled propylene from T103. Also, the effluent passes to a second heat exchanger (E-107) to reduce its
temperature to 78oC by recycled propylene from T-101. The total propylene feed to the
reactor is heated in E-108.
Fig.17:Expoxidation reaction in CRV-101, and recycling propylene produced from T-101 and T103 back to the reactor
The liquid reactor effluent goes to T-101 to separate propylene as an over head
product and PO, EB, MPA, and ACP as bottom product. On the other hand, the vapor
outlet from reactor CRV-100 is fed to second column (T-102) after passing an expander
(K-102) to reduce its pressure to 150 psi so that a mixture of vapor and liquid is created
.propylene and propane are produce as overhead product and fed to the 3rd column (T103), while the bottom product consist of EB and PO. This stream and the bottom
product from previous column are mixed and feed to the 4th column (T-104).
21

Units in this part of the section :
1. Reactor CRV-101:
Fig.18:Reactor CRV-101
2. Distillation Column T-101:
Fig.19:Distillation Column T-101
Fig.20:Connections T-101
22
Fig.21:Monitor T-101
Fig.22:Work sheet T-101
3. Distillation Column T-102:
Fig.23:Distillation Column T-102
23
Fig.24:Connections T-102
Fig.25:Monitor T-102
Fig.26:Work sheet T-102
4. Distillation Column T-103:
24
Fig.27:Distillation Column T-103
Fig.28:Connections T-103
Fig.29:Monitor T-103
25
Fig.30:Work sheet T-103
 Purification of the desired products through out T-104 & preparation of reactants
for the final section:
Fig.31:Purification of the desired products through out T-104 & preparation of reactants for the final
section
As we said before the bottom products from the 1st and 2nd column is fed to (T104) after passing a cooler (E-110) to reduce its temperature then pass through valve
(VLV-103) to reduce its pressure to 24 psi . This column separate PO as overhead
product which is our final product of our process, while the bottom contains ACP, EB
and MBA.
At the end, the bottom product of (T-104) is mixed with EB recycled from (CRV101-2) and fed to (E-111, E-112) to reduce its temperature to 164.4 C. After that its fed to
the final distillation column ( T-105) . The overhead product is ethyl benzene EB while
the bottom is MBA and ACP .

Units in this part of the section :
1. Distillation Column T-104:
26
Fig.32:Distillation Column T-104
Fig.33:Connections T-104
Fig.34:Monitor T-104
27
Fig.35:Work sheet T-104
2. Distillation Column T-105 :
Fig.36:Distillation Column T-105
Fig.37:Connections T-105
28
Fig.38:Monitor T-105
Fig.39:Work sheet T-105

Modification we made to face problems during simulation :
1. Pump (P-102) and compressor (K-103) are used to increase the pressure of the
inlet reactants till the desired operating pressure (P=320 psi).
2. In heat exchanger E-107, there was a problem and massage appeared "correction
factor is low". We fixed it by changing the model of heat exchanger (model:
weighted )
3. In all the recycle of propylene to E-107 and E-108, splitters were used to assist the
conversion of the process.
4. In the 2nd column T-102, we assumed a total condenser instead of a partial
condenser which helped us in the conversion of the column. We neglect the vapor
product from the column (Vent gas).
5. In the 5th column T-105 we neglect the ammonia and catalyst.
6. C-305 and C-306(in actual plant) were reduced to one column T-105 which
separates EB from MBA and ACP .That was done because we neglect the residue.
We assume it has a total condenser not a partial one and we ignored the vacuum
stream.
29

Finding the errors:
Fig.40:Finding the errors
Flow rate
(Ib/h)
Hysis
52585
PO
Actual
50724
Purity
0.9988
0.9998
Error %
3.668875
0.010011
Table 10: Difference between the final product (PO) in real plant & in hysys program
30
 Styrene production section:
Fig.41:Styrene production section
This is the final section of our process. In this section, styrene is produced and
considered as a highly valuable product. It can be divided into 3 parts:
1.
2.
3.
Dehydration reaction in CRV-100-2.
Styrene separation from impurities in successive distillation columns.
Production of more MBA to enhance the yield in a hydrogenation reactor.
 Dehydration reaction in CRV-100-2:
Fig.42:Dehydration reaction in CRV-100-2
The product from the T-105 (stream 23+24) enters a pump (P-107 ) to increase
the pressure from 3.8674 psi to 20 psi . Then the outlet from the pump (P-107) enters the
31
dehydration reactor (CRV-100-2).The bottom product from the reactor goes to a
distillation column (T-101-2) to get styrene from it. The reactor operating temperature
wad decreased so that a liquid flow rate exists. It was modified to 120C after operating at
270 C.
 Styrene separation from impurities in successive distillation columns:
Fig.43: Styrene separation part.
In this part of the final section, styrene is purified in successive distillation
columns. In this part, there are five distillation columns to purify styrene:
1.
2.
3.
4.
5.
T-103-2.
T-101-2.
additional dis.
2nd add.
add.
Fig.44: First three columns of the sections.
32
In the first two distillation columns, they purify styrene from the rector outlet
streams and send then for further purification. The liquid stream goes to T-101-2 to
separate styrene MBA, and ACP, while the vapor product goes to T-101-2 after passing a
cooler (E-104) to separate styrene from water. The bottom product from the T- 101-2 is
sent to a third distillation column (additional dis.) to separate styrene from MBA. Styrene
is the overhead product, and MBA is a bottom product. Styrene streams from T-101-2, T103-2, and additional dis. Are mixed together and sent for further purification.
Fig.45: Last two columns of the sections.
Then the mixture of styrene is introduced to 2 distillation columns for further
purification. The mixture comes from:
1. Overhead product comes from T-101-2.
2. Overhead product comes from T-103-2.
3. Overhead product comes from additional dis.
The mixture is introduced to a pump and a heater to adjust its temperature and
pressure, so that a mixture of vapor and liquid creates. The first column separates styrene
from water, while the second one separates it from ACP. A final product with a perfect
purity is what we get from simulation.
 Production of more MBA to enhance the yield in a hydrogenation reactor:
33
fig:46:Hydrogenation reactor.
As we have said, the third distillation column of the section separates styrene
from MBA, and ACP. The bottom product containing MBA and ACP is sent to the
hydrogenation reactor with EB coming from pervious sections. In order to adjust its
pressure, the stream is introduced to successive pumps to increase its pressure to 1215
psi. Hydrogen feed is introduced to this rector after passing successive compressors in
order to increase its pressure to 1215 psi. The product of this reactor is recycled back to
2nd section.

Modification we made to face problems during simulation :
1. The vapor product from reactor CRV-100-2 goes T-103-2 after passing a
heater to create a liquid/vapor mixture, while the liquid product is
introduced to T-101-2 to separate styrene.
2. The operating temperature of reactor CRV-100-2 was reduced to 120 C to
get a liquid flow.
3. In the actual plant, the liquid product from the reactor goes to a distillation
column to separate toluene from it. Since toluene is not negligible, there is
no need to consider that column. Instead, the liquid flow is sent to T-101-2
as mentioned in modification 1.
4. To increase styrene purity, three additional distillation columns were
added (additional dis., add., 2nd add).
5. Since residue is not defined in our process, there is no need to operate a
distillation to separate the residue. Therefore, ACP column which separate
ACP from residue was not defined.
6. Successive pumps and comprosers were used to increase the feed streams
to the hydrogenation reactor (CRV-101-2).
34

Finding the errors:
Fig.47:Finding the errors
Flow rate
(Ib/h)
Hysis
114167
Purity
1
Styrene
Actual
114065
Error %
0.089423
0.9989
0.110121
Table 11: Difference between the final product (styrene) in real plant & in hysys program.
35

Conclusion :
Hysys is a good program for simulation of chemical process. By comparing the
real results and hysys results, we can have 52585 Ib PO/hr compared to 50724 lb PO/hr
with an error estimated of 3.66%. Also, comparing the styrene production from hysys
program and the real results give us an estimated error of 0.089%. The styrene produced
as estimated from the program is 114167 lb/hr, while 114065 lb/hr in the real plant.
In order to obtain those results, we have modified some of the process conditions,
and some material streams and unit were neglected.
36