UNIVERSITY OF CINCINNATI
CHE Design Project I
Ethyl Benzene Process
20CHE5045
Super Group: Jacob Bolden, Ryan Cage, Connie Crum, Travis Duckro, Matt Miller, Jeremy Schirmer
12/10/2012
0
Contents
Abstract ......................................................................................................................................................... 2
1. Scope Definition ........................................................................................................................................ 3
2. Design Basis............................................................................................................................................... 3
3. Process Description ................................................................................................................................... 4
3.1 Process Synthesis ................................................................................................................................ 4
3.2 Recommended Process ....................................................................................................................... 4
3.3 Process Control Philosophy................................................................................................................. 7
3.4 Environmental Performance ............................................................................................................... 8
3.5 Process Safety ..................................................................................................................................... 8
3.6 Preliminary Equipment Specifications .............................................................................................. 10
4. Process Economics .................................................................................................................................. 15
4.1 Estimated Capital and Operating Costs ............................................................................................ 15
4.2 Economic Analysis ............................................................................................................................. 18
5. Future Work ............................................................................................................................................ 18
6. References .............................................................................................................................................. 18
Appendix A .................................................................................................................................................. 18
Appendix B .................................................................................................................................................. 18
Appendix C .................................................................................................................................................. 18
Appendix D .................................................................................................................................................. 19
Appendix E .................................................................................................................................................. 19
Appendix F .................................................................................................................................................. 19
Appendix G .................................................................................................................................................. 19
1
Abstract
The objective of this project is to design a process to produce 500,000 metric tons/year of ethyl benzene
from a feed of ethylene and benzene. Additionally, we have a toluene mixture in our initial feed stream
that must be removed and sold at greater than 99 weight percent purity. Our final design resulted in a
production of 44,775 metric ton/year of toluene as well as 534,653 metric ton/year of ethylbenzene.
Purification specification is 99.1 weight percent and 99.99 weight percent respectively.
This process has a return on investment of 15.18% and a payback period 3.97 years assuming straightline depreciation of 10%.
Recommendations for future work include further investigating mean by which toluene could be
removed at the end of the process to understand the possible economic benefits. Additionally, more
effort could be spent on temperature control for process monitoring and real-time operational changes.
Finally, the addition of waste streams surrounding column 2 would reduce our cycle-up and effectively
lower the sizing of the column.
2
1. Scope Definition
The purpose of this project was to design a process capable of producing 500,000 metric tons per year
of 99.9 % pure ethylbenzene. Additionally our feed is mixed with toluene and as such must be separated
at a rate that maintains profitability for the process.
Design conditions assume that operation of the plant will occur at 8000 hours per year. Average hourly
feed rate for the benzene/toluene feed is 640 kmol per hour and 60 kmol per hour respectively.
Average hourly feed rate for ethylene is 630 kmol per hour.
Production rate for toluene is approximately 60 kmol per hour and production rate for ethylbenzene is
approximately 630 kmol per hour. Both toluene and ethylbenzene maintain a purity of greater than
99%.
2. Design Basis
The completed process operates with a feed rate of 700 kmol/hour with a composition of benzene at
640 kmol/hour and 60 kmol/hour toluene. The cost for this feedstock is $1,050/metric ton due to the
presence of toluene. This feedstock is stored on-site at 30 degrees Celsius. The ethylene feedstock is
fed into the process at 630 kmol/hour and stored on site at 40 degress Celsius. The cost for ethylene is
$1,220/metric ton.
Product rate for the process is 60 kmol/hour of toluene at a purity of 99.1%, discharged at a
temperature of 39.85 degrees Celsius at 2 atm. The remaining 0.9% is comprised of pure benzene. The
second product rate for this process is the ethylbenzene discharge at 630 kmol/hour. The stream is
discharged at 39.85 degrees Celsius at 2 atm. The composition of this stream contains 0.9999238
ethylbenzene, 1.854871e-008 benzene, 2.244194e-005 toluene, 2.303265e-008 P-Diethylebenzene, and
5.3764e-005 1-Methyl-4-Ethyl.
For our utility considerations, we used low, medium and high pressure stream with respective
temperatures of 160 degrees Celsius, 184 degrees Celsius and 254 degrees Celsius. For our condensers,
cooling water inlet was 90 degrees F and exited at 120 degrees F.
The major by-products in this reaction are diethylbenzene and methylbenzene, but these products are
not a waste stream as they are continuously recycled and reused in the process.
3
For this process, we did not utilize waste streams, rather recycled all reaction products. Although we do
not incur the cost of waste disposal, our column 2 is significantly more expensive due to sizing.
Plant layout would be to keep both reactors and all 3 columns within close proximity to each other for
ease of operator use.
Special safety requirements will be addressed in the PHA summary located later in this report.
3. Process Description
3.1 Process Synthesis
In addition to the final process selected, we had initially went through iterations of a process where the
toluene was removed at the end of the process in a separation between ethylbenzene and toluene,
resulting in two product streams from one distillation column. This proved to be ineffective, as purity
requirements were not able to be achieved with the given separation. It was determined that the
process would not be in our best interest to further investigate, due to time constraints with iterations
to improve separation quality.
3.2 Recommended Process
For our reactors, we decided to use plug flow reactors for ease of catalyst use.
The final design process begins with the benzene/toluene feed located on stream 1. This stream passes
through an economizer (E-1) to become stream 24. Stream 24 is fed into a distillation column (C-1)
where the toluene benzene mixture is separated into stream 2 (the distillate stream which passes
through a condenser) and stream 3 (the bottoms stream which passes through a reboiler).
Stream 3 composition is 99.1% toluene and 0.89% benzene. It is fed into pump P-1 where it becomes
stream 21 to pass through economizer E-1. After economizer E-1 it becomes stream 23 (T-Product) and
sent to a storage tank. Stream 2 (Benzene outlet) is fed through a pump (P-2) where it becomes stream
20 and is fed into a mixer. Additionally, stream 4 is fed into the mixer (M-1) which is the ethylene feed.
One additional stream is included in the mixer, which is a benzene recycle stream , appropriately named
Benzene M-1 inlet, (14,25) from the distillate of column 2. This inlet is preheated through an
economizer (E-3). From mixer M-1 the stream becomes stream 5 to where it is fed into an economizer
4
E-2 to be additionally preheated. After the economizer E-1, the stream becomes stream 16 and is fed
into the heat exchanger HX-1. Stream 16 becomes stream 6 where it is fed into the reactor R-1. The
discharge from R-1 is stream 8 where it is fed into a second reactor, R-2. Additionally, stream 26 named
DEB MEB R-2 is fed into reactor 2 and is the recycle stream from the bottoms of the column C-3. Stream
18 is fed into a pump P-5 to become stream 7, DEB MEB recycle. This recycle stream is preheated with
the economizer E-3 before it is fed into the reactor R-2. Reactor 2 discharge is fed to an expander, EX-1,
where it becomes stream 11 and is fed to the inlet of C-2. The distillate for C-2 has already been
discussed, but the bottoms is stream 13 named EB out (ethylbenzene out). This is fed to pump P-4
where it becomes stream 12 and is the inlet to column 3. The bottoms of C-3 have already been
discussed, and as such the distillate is the product ethyl benzene. It is pumped through P-6 where it
becomes stream 22, EB Product Hot 1. This stream is fed through a series of 1 economizer (E-2) and 1
heat exchanger (HX-2) where it finally becomes stream 19, EB product.
Appendix C located at the end of the report consists of an overall material and energy balance for the
process. A summary is provided below:
5
Table 1 – Stream Specifications
Stream ID
Stream Name
Molar Flow (Kmol/h)
Mass Flow (kg/h)
Flow (gpm)
Temperature (K)
Pressure (atm)
Vapor Mole Fraction
Enthalpy (MMBtu/h)
ID (in)
ID (in) Rounded
Stream ID
Stream Name
Molar Flow (Kmol/h)
Mass Flow (kg/h)
Flow (gpm)
Temperature (K)
Pressure (atm)
Vapor Mole Fraction
Enthalpy (MMBtu/h)
ID (in)
ID (in) Rounded
Stream ID
Stream Name
Molar Flow (Kmol/h)
Mass Flow (kg/h)
Flow (gpm)
Temperature (K)
Pressure (atm)
Vapor Mole Fraction
Enthalpy (MMBtu/h)
ID (in)
ID (in) Rounded
Stream ID
Stream Name
Molar Flow (Kmol/h)
Mass Flow (kg/h)
Flow (gpm)
Temperature (K)
Pressure (atm)
Vapor Mole Fraction
Enthalpy (MMBtu/h)
ID (in)
ID (in) Rounded
Stream ID
Stream Name
Molar Flow (Kmol/h)
Mass Flow (kg/h)
Flow (gpm)
Temperature (K)
Pressure (atm)
1
2
3
4
5
6
Benzene/Tolu Benzene Outl C-1 Bottoms Ethylene Fee Mixed R-1 Fe R-1 Feed
700.0001
639.1602
60.8401
630.6 12071.0596 12071.0596
55525.0898
49928.2109
5596.897 17690.8516
911550
911550
276.8242
248.5608
28.2629
222.5446
4669.0352
4669.0352
303
352.9624
383.3652
313
359.9948
434
1
1
1
29.6
21
20
0
0
0
1
0
0
31.606
34.705
1.568
30.77
661.16
790.91
4.701563045 4.601829805 1.602160861 11.17424436 15.5129682 15.99770695
5
5
2
11.5
16
16
7
8
9
10
11
12
DEB MEB Rec R-1 Out
Benzene out R-2 Out
C-2 Inlet
C-3 Inlet
660.3389
11440.4805 10801.2998 12100.7959
12091.167
1289.8661
88138.0234
911550
843931
999688
998905 154973.2969
447.2481
4539.3628
4197.9302
4986.6226
4982.7114
784.7817
473.3013
434
352.9785
434
358.2408
427.0439
20
20
1
20
1
1.5
0
0
0
0
0.3805
0
-13.984
725.53
586.07
704.53
691.72
-14.143
6.471857527 15.79899527 14.90033742 16.18289987 23.31849869 8.121012168
6.5
16
15
16.5
23.5
8.5
13
14
15
16
17
18
EB Out
Benzene Recy EB Out
E-1 Feed Out EB Product H MEB DEB Out
1289.8661
10801.2998
629.5273 12071.0596
629.5273
660.3389
154973.2969
843931 66835.3047
911550 66835.3047 88138.0234
784.7817
4197.9302
337.5343
4669.0352
337.5343
447.2481
427.0284
353.6168
425.257
364.5097
369.9948
472.5461
1
20
1.5
21
2
1.5
0
0
0
0
0
0
-14.153
587.96
8.5598
668.34
1.3845
-14.208
8.120938661 14.90418568 5.526105078 15.53853167 5.34150458 6.468465552
8.5
15
6
16
5.5
6.5
19
20
21
22
23
24
EB Product
Benzene Out Toluene Out EB Product H T Product
E-1 Feed Out
629.5273
639.1602
60.8401
629.5273
60.8401
700.0001
66835.3047
49928.2109
5596.897 66835.3047
5596.897 55525.0898
337.5343
248.5608
28.2629
337.5343
28.2629
276.8242
313
353.659
383.4007
425.2763
313
311.1573
2
20
2
2
2
1
0
0
0
0
0
0
-5.1135
34.817
1.5687
8.5641
0.89828
32.276
5.184436171 4.603921632 1.602199067 5.526176676 1.535455351 4.723080196
5.5
5
2
6
2
5
25
26
Benzene M-1 DEB MEB R-2
10801.2998
660.3389
6
843931
88138.0234
4197.9302
447.2481
358.9542
434
20
20
A copy of the PFD is attached below:
3.3 Process Control Philosophy
The overall control philosophy is set based upon a set of objectives for the plant. From the initial
problem statement, we understand that we need a composition of 99.9% pure ethylbenzene from our
discharge in addition to 99% pure toluene to be sold. Our process control surrounds maintaining those
variables at optimal efficiency. As such our process control objectives are as follows:
1. Maintaining appropriate stream composition for output of product.
2. Keep the conversion of the plant at its highest permissible value.
3. Achieve constant composition in the liquid effluent from both reactors.
The degree of automation for this process would not need to be too in-depth as it is a basic reaction and
control valves can be used for control of the process. Control valves would need to be located at the
discharge of each unit op, in addition to the feed locations to control reactant flow. Real-time data
would be as follows:
1. Thermocouples on the discharge side of each reactor and distillation column.
2. Flow meters on the discharge end of pumps to maintain understanding of flow rate.
The last process control need would be control valves at key locations within the process loop. These
locations are listed below and reference the PFD.
1.
2.
3.
4.
Stream 1
Stream 2
Stream 3
Stream 19
7
5.
6.
7.
8.
9.
10.
11.
Stream 6
Stream 8
Stream 11
Stream 9
Stream 13
Stream 16
Stream 18
The locations of these control valves are based upon the need to possibly limit discharge from the end
of key unit ops such as reactors and distillation columns. Additionally, these control valves are on the
feed and product of the process.
3.4 Environmental Performance
Environmental performance is essentially non-existent for this process as we do not bleed any of the
excess benzene or by products off during the process. We did this recycle selection to avoid the
incremental cost of dealing with waste disposal. No air emissions are necessary for this process; as such
no costs are incurred.
Environmental risks from using chemicals are prevalent for this process as each chemical has significant
health hazard. To minimize these risks, control valves are put into key locations in response to any kind
of runaway reactor and over pressurization situation. All piping is sized in accordance to specification to
allow for corrosion. By doing this, pipe bursts due to corrosion over time are avoided with proper
maintenance.
3.5 Process Safety
A Process Hazard Analysis (PHA) is an organized and systematic method to identify and analyze the
significance of potential hazards associated with processing or handling highly hazardous chemicals. A
PHA helps when making decisions for improving safety and reducing the consequences of unwanted or
unplanned releases of hazardous chemicals. For this process a What if-PHA was performed to analyze
potential causes and consequences of fires, explosions, releases of toxic or flammable chemicals, and
major spills of hazardous chemicals. It focuses on equipment, instrumentation, utilities, routine and
non-routine human actions, and external factors that might impact the process. Some of the principle
hazards identified in the PHA include overpressure of vessels, corrosion, external forces, spills and basic
equipment failure.
While not a frequently occurring hazard there is always concern that the column or vessels can become
over pressurized due to unforeseen circumstances. This is a very high risk hazard that has potential to be
8
deadly. If a vessel bursts not only is there immediate danger to anyone around but also the contents of
said vessel may be hazardous as well. To prevent this from happening pressure relief valves, set to the
upper limits of the vessels specifications can be implemented to reduce risk of failure.
Working with hazardous materials brings with it added danger of spills and accidental contact along with
the corrosion of the system. Due to the nature of this system corrosion is not likely to occur during the
lifetime of the system. However accidental contact due to bursting of a pipe or leak is a severe hazard.
The chemical components being used have the potential to cause harm to employees that become
exposed as well as harm the environment, and even cause explosions. To prevent this from happening
pipes with sufficient safety factors and thickness should/will be implemented, along with insulation of
pipes. To increase the safety, regular checks of the integrity of the equipment using air need to be
performed.
When designing a plant/ system external factors that are out of man’s control have to be taken into
effect as well. Examples include earthquakes, flooding, and loss of power among others. These external
sources have the potential to become hazards if not properly prepared for. By knowing site location and
possible external forces that the system may come in contact with it can be designed in a safe manner
to prevent any harm. In the case of our system we have accounted for earthquakes or external objects
striking the system by properly choosing materials thick enough to with stand small disturbances from
the outside and in. Also in case of a power outage due to storms or other reasons, so as not to lose
operating time a backup generator should be implemented.
A final component of the system that in was in question is a mechanical equipment failure, involving
anything electrical or mechanical. It was determined that throughout the process with the number of
moving parts present that there is a high risk for failure. At any time a temperature probe may go out, a
valve may stop working or a pump may fail. To prevent this sensors and alarms are in place so that if a
mechanical failure occurs the operators would be notified and able to fix it before damage is done.
If the system is designed, built and run to appropriate standards as set forth in the design specs the
hazard risks are greatly reduced.
Table 2 – Hazards and Safeguards
Hazard
Safeguards
Excessive Pressure
Pressure relief valves
9
Equipment Failure
Corrosion
Power outage
Slips/Falls
Accidental contact
with system piping
Alarms to alert operator
Correct piping size and thickness, periodical checks of integrity
Back-up generator to run important system components
Handrails/Guardrails/Non-slip surfaces
Insulated piping
3.6 Preliminary Equipment Specifications
Vessels
Table 3 – Vessel Specifications – Reactor 1
Reactor R-1
Operating Pressure (atm)
Design Pressure (psig)
Operating Temperature (K)
Design Temperature (K)
Inside Diameter (rounded) (ft)
Length (ft)
Wall Thickness (in)
Corrosion Allowance (in)
Weight (lb)
Material
Bed Height
Bed Configuration
Control(s) Location
Alarm(s)
20
336.3
434
450
7.66
80
1.3125
0.125
122972.7
304 SS
N/A
N/A
Outlet
Temperature
Table 4 - Vessel Specifications – Reactor 2
Reactor R-2
Operating Pressure (atm)
Design Pressure (psig)
Operating Temperature (K)
20
336.3
434
10
Design Temperature (K)
Inside Diameter (rounded) (ft)
Length (ft)
Wall Thickness (in)
Corrosion Allowance (in)
Weight (lb)
Material
Bed Height
Bed Configuration
Control(s) Location
Alarm(s)
450
4.83
50
1.3125
0.125
60287.6
304 SS
N/A
N/A
Outlet
Temperature
Table 5 - Vessel Specifications – Column 1
Column C-1
Operating Pressure (psia)
Design Pressure (psig)
Operating Temperature (K)
Design Temperature (K)
Inside Diameter (rounded) (ft)
Height (ft)
Wall Thickness (in)
Corrosion Allowance (in)
Weight (lb)
Material
Number of Trays
Feed Tray Location
Tray Spacing (in)
Bed Height
Bed Configuration
14.7
15
383.9
500
12
98
0.25
0.125
42422.6
304 SS
40
16
24
N/A
N/A
Control(s) Location
Distillate &
Bottoms
Discharge
Alarm(s)
Temperature
Table 6 - Vessel Specifications – Column 2
Column C-2
Operating Pressure (psia)
Design Pressure (psig)
Operating Temperature (K)
Design Temperature (K)
14.7
15
412.6
500
11
Inside Diameter (rounded) (ft)
Height (ft)
Wall Thickness (in)
Corrosion Allowance (in)
Weight (lb)
Material
Number of Trays
Feed Tray Location
Tray Spacing (in)
Bed Height
Bed Configuration
32.5
94
0.3125
0.125
160019.5
304 SS
38
16
24
N/A
N/A
Control(s) Location
Distillate &
Bottoms
Discharge
Alarm(s)
Temperature
Table 7 - Vessel Specifications – Column 3
Column C-3
Operating Pressure (psia)
Design Pressure (psig)
14.7
15
Operating Temperature (K)
450
Design Temperature (K)
500
Inside Diameter (rounded) (ft)
17
Height (ft)
100
Wall Thickness (in)
Corrosion Allowance (in)
Weight (lb)
Material
Number of Trays
Feed Tray Location
Tray Spacing (in)
Bed Height
Bed Configuration
0.3125
0.125
76296.2
304 SS
41
16
24
N/A
N/A
Control(s) Location
Distillate &
Bottoms
Discharge
Alarm(s)
Temperature
Heat Exchangers
Table 8 - Heat Exchanger Specifications – HX-1
12
Type
Flow (kg/hr)
Heat Exchanger HX-1
Shell-and-Tube
910841
Temperature Hin (K)
527.00
Temperature Hout (K)
374.51
Temperature Cin (K)
364.51
Temperature Cout (K)
434.00
Fouling Factors (m2K/W)
Operating Temperature
Design Temperature (K)
Operating Pressure (atm)
Design Pressure (atm)
Material of Construction
Corrosion Allowance
Special Considerations
0.00018
N/A
550
21
25
Stainless steel
0.125
None
Table 9 - Heat Exchanger Specifications – HX-2
Type
Flow (kg/hr)
Heat Exchanger HX-2
Shell-and-Tube
66834.14
Temperature Hin (K)
369.99
Temperature Hout (K)
313.00
Temperature Cin (K)
303.15
Temperature Cout (K)
323.15
2
Fouling Factors (m K/W)
Operating Temperature
Design Temperature (K)
Operating Pressure (atm)
Design Pressure (atm)
Material of Construction
Corrosion Allowance
Special Considerations
0.00018
N/A
400
2
5
Stainless steel
0.125
None
Table 10 - Heat Exchanger Specifications – E-1
Economizer E-1
Type
Flow (kg/hr)
Temperature Hin (K)
Temperature Hout (K)
Shell-andTube
61122.0647
383.40
313.00
13
Temperature Cin (K)
Temperature Cout (K)
Fouling Factors (m2K/W)
Operating Temperature
Design Temperature (K)
Operating Pressure (atm)
Design Pressure (atm)
Material of Construction
Corrosion Allowance
Special Considerations
303.00
311.16
0.00035
N/A
400
2
5
Stainless steel
0.125
None
Table 11 - Heat Exchanger Specifications – E-2
Economizer E-2
Type
Flow (kg/hr)
Temperature Hin (K)
Temperature Hout (K)
Temperature Cin (K)
Temperature Cout (K)
Fouling Factors (m2K/W)
Operating Temperature
Design Temperature (K)
Operating Pressure (atm)
Design Pressure (atm)
Material of Construction
Corrosion Allowance
Special Considerations
Shell-andTube
977675.14
425.28
369.99
359.99
364.51
0.00018
N/A
450
21
25
Stainless steel
0.125
None
Table 12 - Heat Exchanger Specifications – E-3
Economizer E-3
Type
Shell-and14
Tube
Flow (kg/hr)
931287
Temperature Hin (K)
473.30
Temperature Hout (K)
434.00
Temperature Cin (K)
353.62
Temperature Cout (K)
358.95
Fouling Factors (m2K/W)
Operating Temperature
Design Temperature (K)
Operating Pressure (atm)
Design Pressure (atm)
Material of Construction
Corrosion Allowance
Special Considerations
0.00018
N/A
500
20
25
Stainless steel
0.125
None
Pumps
Table 13 – Pumps Specification – P-1 through P-6
Pumps
Name
P-1
P-2
P-3
T (K)
383.4
352.9
Flow (lbmol/hr)
134.1312
1409.1022
Pressure Drop (psi)
50
50
Pump Head (ft)
132.4541284
130.6561086
Specific Gravity
0.872
0.884
Density
0.7806625
0.8154425
Pump Brake Hpr (Pb)
13869.43046
150129.3329
Fractional Efficiency of Pump (np)
0.572710166
0.794910059
Fractional Efficiency of Motor (nm)
0.938692103
0.92165934
Power Consumption (Pc)
0.781783736
6.209593832
Sparing Requirement
Material
304 SS
304 SS
304 SS
Pump Type
centrifigul pump centrifigul pump centrifigul pump
Line Materials
99% Toluene/ 1% Benzene
Benzene/Tolueneall
Line Number
3 and 21
2 and 20
9 and 14
Special Considerations
Special Seal requirements
P-4
352.9
23792.7695
50
130.6561086
0.884
0.8154238
2534884.055
0.886455656
0.874655818
99.07177753
P-5
P-6
427
2842.4392
50
132.9113924
0.869
0.7439471
281057.6734
0.83551416
0.91374121
11.15589661
472.5
1454.5959
50
133.2179931
0.867
0.7001003
135664.2785
0.797003961
0.922804357
5.589609308
304 SS
centrifigul pump
All but Ethylene
13 and 12
304 SS
centrifigul pump
All but Ethylene
18 and 7
425.3
1387.8459
50
132.4541284
0.872
0.7435676
136686.9975
0.793899867
0.92272076
5.654279112
304 SS
centrifigul pump
All but Ethylene
15 and 22
4. Process Economics
4.1 Estimated Capital and Operating Costs
The following table summarizes are total capital cost. At a CE Index of 500 are total purchase cost is
approximately 14 million dollars. When the cost is scaled to a CE index of 593, it raises to approximately
16.5 million dollars. An additional operating cost will be located after the capital cost sheet.
15
Table 14 – Total Purchase Cost
Total Purshase Cost
Columns
C1
C2
C3
Total columns
$
538,275.19
$ 10,566,010.54
$ 1,249,112.34
$ 12,353,398.08
Reactors
R1
R2
Total Reactors
$
$
$
413,983.70
246,927.36
660,911.06
Heat Exchangers
HX1
HX2
E-1
E-2
E-3
Total heat exchangers
$
$
$
$
$
$
415,758.33
65,469.86
34,338.94
75,436.51
43,504.76
634,508.39
Pumps and fans
P-1
P-2
P-3
P-4
P-5
P-6
Total pumps and fans
$
$
$
$
$
$
$
8,455.74
6,422.00
75,330.42
6,819.05
6,380.65
6,390.13
109,797.99
Expander
$
1.00
Total Purshase Cost (CE Index 500)
$ 13,758,616.52
Total Purshase Cost (2012 CE Index 593)
$ 16,317,719.19
Total Capital Investment, TTCI
$ 101,602,278.55 *uses Lang Factor of 5.93
Total Permanent Investment, TTPI
$ 86,353,369.97 *uses Lang Factor of 5.04
16
Table 15 – Cost Sheet Outline
17
4.2 Economic Analysis
For this process selection, it has been determined that the payback period will be approximately 4.28
years and with a return on investment of 15.18%. The venture profit for this process is $158.539. All
sample calculations can be found in Appendix G.
5. Future Work
There are a few open issues and areas of major uncertainty for this process. One of the largest issues
that this process has is its energy usage. One column alone has a duty of over 500 MMBTu/hr which
simply is not economically feasible. The reason for these duties is due to the reflux rate of the column
and the overall mass flow rate. The columns we have designed for this process are rather large in terms
of industry standards and as such the columns and reboilers have high duties.
Additional work could be done in investigating the need for a waste stream for the excess benzene.
6. References
1. Seider, Warren D., J. D. Seader, and Daniel R. Lewin. Product And Process Design Principles,
Synthesis, Analysis, And Evaluation. 3rd ed. Wiley, 2008. Print.
2. Lubyen Paper
Appendix A
Benzene.pdf
Diethylbenzene.pdf
ethylbenzene.pdf
Ethylene.pdf
p-ethyltoluene.pdf
Toluene.pdf
Appendix B
physical
properties.xlsx
Appendix C
Material and Energy
Balances.xlsx
18
Appendix D
Appendix E
No emission calculations were completed for this report as we are a no discharge facility.
Appendix F
ePHA-UC Project
II.xlsx
Appendix G
Process Design Final
Economic Analysis 2.xlsx
19
20