Plant Design 1 Project Report
Plant Design 1 Project Report
Plant Design 1 Project Report
Plant Design I
Group 2
Allison Erwin
Heather Jasken
Jung Mour
Long Nguyen
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Table of Contents
1. Executive Summary ......................................................................................................................... 4
2. Introduction ...................................................................................................................................... 5
3. Summary .......................................................................................................................................... 7
4. Process Design ................................................................................................................................ 8
4.1 Process PFD with Mass and Energy Balances (Simulation) .............................................. 8
Figure 4.1.a: Overall process flow diagram for the ethylene plant .................................................. 8
4.2 Reaction Chemistry ............................................................................................................. 9
4.2.i Furnace ..................................................................................................................................... 9
4.2.ii Acetylene Reactor ................................................................................................................... 10
4.2.iii Methylacetylene & Propadiene (MAPD) Reactor .................................................................... 10
4.2.iv Caustic Scrubber ..................................................................................................................... 11
4.3 Design Specifications Overview ........................................................................................ 12
4.4 Raw Materials ................................................................................................................... 22
4.5 Design of Major Process Equipment................................................................................. 23
4.5.i Heat Exchangers & Condenser ............................................................................................... 23
4.5.ii Pressure Vessels .................................................................................................................... 23
4.5.iii Columns .................................................................................................................................. 24
4.5.iv Compressors ........................................................................................................................... 24
4.5.v Furnaces ................................................................................................................................. 25
4.5.vi Reactors .................................................................................................................................. 25
4.5.vii Dryers .................................................................................................................................. 25
4.5.ix Pumps ..................................................................................................................................... 25
4.5.x Separators ............................................................................................................................... 26
4.6 Operating Labor Requirements ......................................................................................... 27
5. Economics ...................................................................................................................................... 28
5.1 Heat Exchangers & Condensers....................................................................................... 30
5.2 Pressure Vessels .............................................................................................................. 32
5.3 Columns and Trays ........................................................................................................... 34
5.4 Compressors ..................................................................................................................... 38
5.5 Furnaces ........................................................................................................................... 41
5.6 Reactors ............................................................................................................................ 42
5.7 Dryers ................................................................................................................................ 43
5.8 Pumps ............................................................................................................................... 44
5.9 Separators ......................................................................................................................... 45
5.10 Raw Materials ................................................................................................................... 46
5.11 Utilities ............................................................................................................................... 48
5.12 Operating Labor ................................................................................................................ 50
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6. SAFETY ......................................................................................................................................... 52
6.1 Personal Protective Equipment (PPE) .............................................................................. 52
6.1 Personal Protective Equipment (PPE) (cont.) ................................................................... 53
6.2 HAZOP .............................................................................................................................. 54
7. Environmental ................................................................................................................................ 62
7.1 Emissions and Effluents Control ....................................................................................... 62
7.2 Water Quality Control ........................................................................................................ 63
7.3 Noise Level Control ........................................................................................................... 64
8. Societal Responsibility ................................................................................................................... 65
9. Conclusion ..................................................................................................................................... 66
11. Appendix ........................................................................................................................................ 68
11.1 Appendix A: Economic Calculations ................................................................................. 68
11.2 Appendix B: Raw Material Calculations ............................................................................ 68
11.3 Appendix C: Equipment Sizing and Pricing ...................................................................... 71
11.4 Appendix D: Operating Utility Costs .................................................................................. 97
11.5 Appendix E: Operating Labor Costs ................................................................................. 98
11.6 Appendix F: Chemical MSDS Sheets ............................................................................... 99
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1. Executive Summary
Aspen Plus V7.1 was used to simulate the front-end of an ethylene plant. Using
the McGraw Hill Online Cost Estimator the plant is estimated to have a fixed-capital
investment (FCI) cost of $361.3 million with equipment costs at approximately twenty
percent of the FCI. All equipment and material costs are scaled to 2010 prices using
Marshall and Swift install-equipment indices. The facility was designed to run a fresh
feed of 70/30 wt% ethane/propane (EP) at a rate of 90,000 kg/hr, producing roughly
62,500 kg/hr of ethylene. The portions of the plant simulated ranged from the furnace
up to the cold box and is expected to operate 350 days a year with 15 days of
scheduled downtime.
Based on the results from the simulation it was found that the same
specifications of ethylene can be reached using a feed other than pure propane. This is
useful information because the facility could change its feed composition based on the
market prices of eligible feed. Furthermore, the simulated plant only needed 90,000
kg/hr of 70/30 EP feed where the given plant in chapter three of Plant Design and
Economics for Chemical Engineers required 146,000 kg/hr of pure propane to produce
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2. Introduction
many types of processes such as low pressure steam pyrolysis of light hydrocarbons,
naphtha, and gas oils. Production of ethylene can also be accomplished through
separation from a catalytic cracking unit effluent; however, this method is not efficient if
the primary desired product is ethylene. The most efficient process is through steam
pyrolysis, also known as steam cracking. The top three commercial applications of this
piping, respectively, as well as many other products. Since this is a practice commonly
used in industry, a case study of this process is illustrated throughout this report.
to 1.2 billion pounds of ethylene a year. The main objective is to simulate an ethylene
plant that produces 62,000 kg/hr base from feedstock comprised of an E/P (ethane-
propane) mixture. This E/P mixture is a 70/30 wt% mixture, respectively, based on mass
percentages. Tasks within the project consist of simulating and costing the front end
sections of the process, up to the Cold Box section. Several key areas of this process
are incorporated in detail though out this case study, including cracking, quenching,
sections.
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One of the key components to this process is the hot section, which creates the
products as well as the steam for the plant. Then there is the cold section, which
handles the separations of the components. Furthermore, there are multiple heat
integrations and refrigeration units throughout the site. This process utilizes low
pressure (LP) and medium pressure (MP) steam, along with different grades of C2 and
C3 refrigerate.
Many other aspects to a safe and environmental friendly facility are vital to be a
community, a HAZOP study is included for all areas of the process that was simulated.
receptors, and process alarms are put in place to ensure safety. Records of the Material
Safety Data Sheets (MSDS) are made available to the public to keep the community
educated of the chemicals used in the area. Safety is made the top priority of this
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3. Summary
This project looked to simulate the front-end part of an ethylene plant using an
ethane-propane feed mixture. With worldwide demand of ethylene so high, the designed
ethylene plant would need to produce 62,500 kg/hr, totaling 1.2 billion tons of ethylene
per year. To simulate the plant, the plant design textbook was used as a reference for
design specifics such as temperature, pressure, and the process flow of the plant. Raw
materials were calculated based on the flow rate of material, and reaction chemistry
The major pieces of equipment were sized based off of various parameters, such
as volumetric and mass flowrates, using engineering techniques. Once the equipment
had been sized, costs for each piece of equipment were evaluated using the online cost
estimator provided by McGraw-Hill. The FCI was then calculated based on the total
equipment prices. All costs were scaled to the 2010 estimated value based on the
Marshall and Swift installed-equipment indexes (see Appendix A). Labor costs were
With the employees and the community in mind, safety was considered first and
foremost in designing this ethylene plant. Material Safety Data Sheets for the chemicals
in the plant were assembled to determine what personal protective equipment should be
worn in each of the various process areas. In addition, brief HAZOPs were developed
for the major pieces of equipment in the plant. Lastly, environmental standards were
compiled to ensure that the plant operates in compliance with government standards,
such as the noise level guidelines as set forth by OSHA and the EPA. These guidelines
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4. Process Design
4.1 Process PFD with Mass and Energy Balances (Simulation)
Figure 4.1.a: Overall process flow diagram for the ethylene plant
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4.2 Reaction Chemistry
4.2.i Furnace
The feedstock contains both ethane and propane in the mixture. The primary reactions
Ethane to ethylene:
C2H6 ↔ C2H4 + H2
C3H8 ↔ C3H6 + H2
Chemistry of steam cracking involves breaking of large molecules into smaller, more
useful molecules. This process is accomplished through high temperatures and high
pressures. Figure 4.2.a illustrates the cracking of ethane into ethylene with hydrogen as
the by-product.
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The reaction takes place in the radiation section of the furnace (F-101, A-H) at
temperatures around 835°C and pressures around 170 kPa. Through the steam
cracking, ethylene is the primary product; however, other by-products are created. The
products from the furnace need to go through a purification process to acquire the
The point of the acetylene reactor is to maximize profits by taking byproducts and
turning them into useful products. Additionally, an acetylene converter will prevent off-
C2H4 + H2 ↔ C2H6
This reactor was not modeled in the simulation; however, the reaction chemistry is still
C3H4 + H2 ↔ C3H6
C3H6 + H2 ↔ C3H8
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4.2.iv Caustic Scrubber
Removing H2S and CO2 from the process is vital in preventing production of off-spec
product. CO2 in particular needs to be removed before reaching the cold box. To
remove hydrogen sulfide and carbon dioxide from the process, a caustic scrubber is
needed. A 50% sodium hydroxide stream is fed into the caustic scrubber and reacts
with the hydrogen sulfide and carbon dioxide to form sodium sulfide, sodium carbonate,
and water.
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4.3 Design Specifications Overview
This section covers the initial and basic plant design schematics of a
conventional ethylene plant from the Peters, Timmerhaus, West Plant Design and
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Table 4.3.a – Cracking Section Initial Parameters
CRACKING SECTION
INLET OUTLET TEMP PRESSURE
BLOCK ID EQUIPMENT NAME/PURPOSE
STREAMS STREAMS [degC] [kPa]
PRIMARY EQUIPMENT
V-101 FEEDSTOCK DRUM 105 41 579
106-108 41 579
107-109 41 579
110 4 565
V-102 (A-H) STEAM DRUMS 113 149 8651
114 300 8637
F-101 (A-H) CRACKING FURNACES 111 83 551
112 835 172
E-103 (A-P) TRANSFER LINE EXCHANGERS 112 835 172
114 149 8651
114 300 8637
116 338 165
SECONDARY EQUIPMENT
E-101 (A-C) EXCHANGERS 107
109
E-102 HEAT EXCHANGER 110 4 565
111 83 551
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4.3.ii - Quenching Section
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Table 4.3.b - Quenching Section Initial Parameters
QUENCHING SECTION
INLET OUTLET TEMP PRESSURE
BLOCK ID EQUIPMENT NAME/PURPOSE
STREAMS STREAMS [degC] [kPa]
PRIMARY EQUIPMENT
S-201 OIL SEPARATOR 207 - -
209 - -
210 - -
C-201 QUENCH TOUR 201 232 152
204 35 138
205 50 152
206 112 152
202 39 131
203
C-202 PROCESS WATER STRIPPER 218
219
322 33 152
220 116 172
206 112 152
SECONDARY EQUIPMENT
E-201 (A-B) EXCHANGER 116 338 165
223 540
201 232 152
225 540
merged 226 166 538
E-202 (A-B) EXCHANGER 222 540
224 -
E-203 (A-D) EXCHANGER 213 80 152
205 50 152
E-204 (A-D) EXCHANGER 217 50 152
204 35 138
E-205 REBOILER - 116 172
- 116 172
E-206 EXCHANGER 209 - -
227 - -
P-201 (A-B) PUMP 210 - -
211 - -
P-202 PUMP 220 116 172
221 - -
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4.3.iii - Compression & Acid Gas Removal Section
Figure 4.3.c – Process Flow Diagram for the Compression & Acid Gas Removal Section
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Table 4.3.c - Compression and Acid Gas Removal Initial Parameters
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Table 4.3.c - Compression and Acid Gas Removal Initial Parameters (continued)
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4.3.iv – Drying, Deethanization & Acetylene Hydrogenation Section
Figure 4.3.d – Process Flow Diagram for the Drying, Deethanization & Acetylene Hydrogenation Section
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Table 4.3.d - Drying, Deethanization and Acetylene Hydrogenation Initial Parameters
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Table 4.3.d - Drying, Deethanization and Acetylene Hydrogenation Initial Parameters
(Continued)
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4.4 Raw Materials
Raw materials:
Feedstock:
Inlet temperature: 41 °C
Composition:
Ethane: 70 wt%
Propane: 30 wt%
Flow rates:
Phase:
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4.5 Design of Major Process Equipment
Cooling water exchangers (E-204, E-203, E-302, E-303, E-304, & E-401(A&B))
were designed based on the duty required to cool the process fluid to the outlet stream
spec. The cooling water streams were run at 29°C and 450 kPa. The cooling water
for the process. Using these parameters the exchangers were simulated and costed.
E-102 was simulated using aspen to heat the feed from 4°C to 83°C.
All Reboiler & Condensers were simulated with the columns and thus were
E-403 & E-409 were designed based on the flows necessary for the main
E-202, E-205, & E-301 were contingencies in the total exchanger costs as the
V-301, V-302, V-302, V-303, & V-401 are designed based on the flash
parameters for each drum. Furthermore, they were sized to hold 4 minutes of the total
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4.5.iii Columns
The quench tower (C-201) was sized using four 3-phase flash drums. These
drums were sized to completely fill up in four minutes based off of volumetric flow rate
into the drum. The drums were simulated to model stream 202 with the temperature of
39°C. They were sized to hold 4 minutes of the total volumetric flow rate into the drum.
The total cost of the quench tower was based off the total prices of the 4 drums.
The caustic scrubber (C-302) was simulated as a separator to remove CO2 and
H2S.
The primary deethanizer (C-401) was designed with 9 trays. Furthermore this
without sending any offspec amount of the C2 and lighter components. In addition, the
primary de-ethanizer is designed to reduce the heat duty in C-402 and allow for a more
efficient cut.
The deethanizer column (C-402) was designed to separate the Ethane and the
lighter components overhead white sending the C3 and heavier components down to
the C-604. A key design spec is to make sure that any amount of C2 and lighters sent
4.5.iv Compressors
The Charge Gas Compressors are designed to take in vapor at a specific pressure and
temperature range and then doubles the pressure. For example, the 1st stage
compressor takes feed at 131 kPa and compresses the process material to 234 kPa.
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Each compressor is designed to double the pressure is to allow for an efficient duty.
4.5.v Furnaces
The furnaces were designed as two R-Yield reactions. One for ethane and one for
propane to get the necessary material balance. The furnaces were sized based on the
feed flow rate with respect to the duty per flow rate to the furnaces.
4.5.vi Reactors
R-401 was designed as an R-Stoic reactor with 0.9999 conversion of acetylene. R-401
4.5.vii Dryers
D-401(A&B) and D-401(A&B) were designed to separate any water left in the process
4.5.ix Pumps
P-201, P-202, P-304, and P-305 were not simulated, but the streams that were there
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4.5.x Separators
The separators were sized based on the method found in the referenced Coulson and
determine which phase was dispersed, which allowed the derivation of the dispersed
phase settling time. Next, the interfacial area, the decanter length required for
coalescing the dispersed phase, and the total length of the decanter were calculated.
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4.6 Operating Labor Requirements
The operating labor economics, found in section 5.12, were based on the following
assumptions:
15 workers/shift
12 hr/shift
2 shifts/day
4.7 Utilities
Cooling water exchangers (E-204, E-203, E-302, E-303, E-304, & E-401(A&B)) were
designed based on the duty required to cool the process fluid to the outlet stream spec.
The cooling water streams were run at 29°C and 450 kPa. The cooling water outlet
streams were allowed a maximum change of 11°. Furthermore, for the Quench tower
cooling water exchangers (E-203 & E-204) the flows in each of these exchangers were
split between four exchangers because E-203 & E-204 have A-D. Thus the simulation
models only a fourth of the flowrate into the exchangers, but was accounted for in the
cost.
Refer to Table 5.11.a from section 5.11. See Table of Contents for page location.
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5. Economics
All prices, unless specified, were obtained using the Marshall & Swift cost indexes found
Appendix A section 11.1 (see Table of Contents for page number) and the McGraw Hill
online cost estimator tool. This tool only derived values for 2002, so all prices obtained
The overall costs of equipment and the total FCI for the simulated ethylene plant are
below in Table 5.1.a and Table 5.1.b. These costs differ from the provided values in
chapter 3 of the text because only the front-end of the plant was simulated and clear
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Table 5.b - Purchased Equipment Cost
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5.1 Heat Exchangers & Condensers
The costs of exchangers were based on the exchanger area. Furthermore, the
exchanger material was chosen based on if the system was cold service or hot service.
general, if the exchanger ran using cold service, then the material chosen was stainless
steel; otherwise, carbon steel was chosen. For the exchangers that lacked information
vital for sizing, contingencies were necessary to account for the prices. Sizing and cost
information for each exchanger is illustrated on the following page in Table 5.1.a.
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Table 5.1.a - Economics on Exchangers & Condensers
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5.2 Pressure Vessels
Pressure vessels were sized depending on the time required to hold the total volume
coming into the vessel. It was assumed that in four minutes, the drum would be
completely filled. With this assumption a volume of the equipment was obtained. Using
this volume, a cost was determined with the McGraw Hill Online Cost Estimator.
Unfortunately, a specific pressure vessel estimator was not available and all the vessel
costs were estimated using a carbon steel, large or small field-erected storage tank; the
exception being V-401, using stainless steel material due to cold service. Sizing and
cost information for the pressure vessels are illustrated on the following page in Table
5.2.a.
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Table 5.2.a: Economics of Pressure Vessels
Block V-301
Parameter / Stream 303 315
Volume Flow [m3/hr] 142223.82 1.80
Total Flow Inlet [m3/hr] 142225.62
Volume [m3] 9481.71
Cost (2002) $458,728
Present Value (2010 Value) $606,395
Block V-302
Parameter / Stream 306 310
Volume Flow [m3/hr] 110439.17 0.98
Total Flow Inlet [m3/hr] 110440.14
Volume [m3] 7362.68
Cost (2002) $379,417
Present Value (2010 Value) $501,553
Block V-303
Parameter / Stream 309
Volume Flow [m3/hr] 33876.32
Total Flow Inlet [m3/hr] 33876.32
Volume [m3] 2258.42
Cost (2002) $137,276
Present Value (2010 Value) $181,466
Block V-401
Parameter / Stream 402
Volume Flow [m3/hr] 70297.58
Total Flow Inlet [m3/hr] 70297.58
Volume [m3] 4686.51
Cost (2002) $279,266
Present Value (2010 Value) $369,163
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5.3 Columns and Trays
The quench tower (C-201) was sized using four 3-phase flash drums. These drums
were sized to completely fill up in four minutes based off of volumetric flow rate into the
drum. Each individual drum was sized using the online cost estimator. Like the
pressure vessels, the drums were sized using carbon steel field-erected storage tanks.
The prices obtained for these drums were then added to together to get an overall cost
The caustic scrubber (C-302) was sized using a packed column. The time
required to fill the liquid space in the drum was assumed by estimating that it would take
10 minutes for the liquid level to reach the packing. Likewise, the vapor was estimated
to fill the drum in one minute, not accounting for the packing space. The volume was
then calculated based on the estimated times and volumetric flowrates of liquid and
vapor, respectively. Using the volume calculated and an assumed diameter, a height
was then obtained. The diameter and the height were then used in calculating the price
for the column. Since the column is packed, the packing also needed to be priced.
Assuming a 5 meter liquid space and a 3 meter vapor space, a packing height was
estimated based off the total column height. Assuming porcelain packing, the price of
packing was then determined. The overall column cost was calculated by adding the
The primary deethanizer (C-401) was designed with 8 trays, but 20 trays were
used to cost the column, taking into account for inefficiencies in Aspen. The diameter of
this column was given by Aspen, and a height of 15.24 meters was calculated from tray
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spacing and number of trays. The trays and the column itself were priced using the
online cost estimator individually and then totaled to get an overall price for the column.
The methods of costing the deethanizer column (C-402) were exactly like the
ones used to cost the primary deethanizer column. A diameter was acquired from
aspen, and using the number of trays and tray spacing the C-402 was determined to
have a height of 43.28 m. The column and trays were then priced individually and an
Top &
Bottom
Tray Number Cost of 2002 2010 Value
Diameter Space Height Cost of
Block ID Spacing of Trays Trays or Value of of Column
(m) of (m) Column
(m) (N) Packing Column(s) ($)
Column
(m)
C-401 0.61 0.6096 20 3.048 15.24 $351,718 $17,469 $369,187 $488,030
C-402 3.67 0.6096 66 3.048 43.28 $2,239,623 $224,582 $2,464,205 $3,257,444
C-201 See Figures 5.3(b-e) $2,734,207 $3,614,361
C-302 2.50 8 30.00 $1,585,078 $78,612 $1,663,690 $2,199,240
C-202 Contingency $1,000,000
C-301 Contingency $1,000,000
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Table 5.3.b - Parameters & Cost of Column C-201A
C-201A
C-201B
Parameters / Streams 201C-B 205 HCA-B RFLXA-B
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Table 5.3.d - Parameters & Cost of Column C-201C
C-201C
Parameters / Streams 201D-C 206 HCB-C RFLXB-C
C-201D
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5.4 Compressors
The disparity in economics between the simulated compressors and the values in
the book are due to the change in flow rates and the fact that at least two other
compressors were not cost. Furthermore, the cost of the compressors in the plant
design book may have included the costs of the turbine which would have been the
Sizing/costing each compressor required the net work from Aspen. For instance,
the K-303 compressor was simulated with a net work of over 6000 kW. This is due to
the fact that the SRK package would not allow for the overhead vapor flow rate of the
drums to flash at the specified temperature. In addition, the McGraw Hill cost estimator
would not allow for a compressor to be cost at above 6000kPa. For a costing stand
point, a net work of 5999 kW was used to get an approximate number. While the K-303
compressor should not need that much energy, the values displayed in the figures
below demonstrate that at a material temperature of 33°C, the output of the compressor
is less than 6000kPa.For information related to the compressors see Table 5.4.a. The
information utilized from the Aspen Plus 7.1 simulation is illustrated on the following
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Figure 5.4.a - Simulated Compressor Input
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Table 5.4.a: Economics of Compressors
Block K-301
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5.5 Furnaces
Furnace costs were larger than book values even though the flow rates and heat
duty was less. This may be because of the specific materials used to size the furnaces.
The furnace cost was calculated based on a total flow rate of 137,418kg/hr. The
flow rate of the furnace in chapter 3 of the Peters, Timmerhaus, and West Plant Design
& Economics, 5th edition textbook, had a total flow rate of 174,115 kg/hr with a total duty
of 374,478 kW. Calculating the duty per kg/hr of material allowed for the calculation of
the simulated furnace duty. The data relating to the furnace cost calculated is displayed
in Table 5.5.a.
F-101
Ch. 3 Furnace Simulated Furnace
Flow rate [kg/hr] 174115.00 137418.00
Duty [KW] 374478.00 295551.89
Duty/furnace [KW] 42221.70
Cost of 1 Furnace $2,679,776
Cost of 8 Furnaces $21,438,208
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5.6 Reactors
The cost of reactors in chapter three of the Plant Design & Economics for Chemical
Engineers textbook were used in a proportion to determine the costs of the acetylene
reactor simulated. Calculations of the flow rate into the MAPD converters were
necessary to properly determine the cost for each kg/hr of material flow. Information on
R-401
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5.7 Dryers
To determine the volume of both the liquid and gas dryers the amount of water being
removed from the dryers was simulated in Aspen. Then, using the ratios provided by
Peters et al. on page 109 the volume was calculated. Assuming a height for the dryers,
their areas were then derived. The areas were used in the cost estimator tool and a
price was obtained. The price for each liquid and gas dryer was then multiplied by 3 to
get the overall costs of all dryers. For information related to the dryers see Table 5.7.a.
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5.8 Pumps
The pumps were sized based on the volumetric flow rate into the pump and the
discharge pressure. The online cost estimator was once again used to determine the
cost of each pump. All pumps were assumed to be horizontal or centrifugal. The
materials for the pump casings were iron, cast steel, or cast iron. For information
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5.9 Separators
The costs of these separators are based on the diameter calculated for each drum.
Block S-401 was sized at a diameter of 0.9774 meters, which led to a present value
(2010) equipment cost of $228,512. Block S-201 used contingency to account for the
S-401
S-201
Contingency
Cost (2010) $230,000
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5.10 Raw Materials
The values found in Table 5.10.a were based off of 2012 prices of ethane and propane
(Detrow) and 2000 prices of caustic (Peters, Timmerhaus, West). Once the prices per
kg of material were determined, the price was then multiplied by the mass flowrate to
get an overall cost. The flowrates used in the calculations were determined from the
Aspen simulation. The costs for the three raw materials were then summed to get an
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Table 5.10.a – Raw Material Economics
Propane
Ethane
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5.11 Utilities
The cost of utilizes is calculated based on the amount of cooling water flow rates
in each exchanger, requiring cooling water. In Table 5.6.a, the flow rates in kg/hr are
illustrated for all cooling water streams. The name of the stream is in reference to the
AspenPlus 7.1 simulation. Flow sheets are available for reference in the appendices
The market price of cooling water was found to be at $0.08/ per 1000 kg of
cooling water used. This information was obtained in the Peters, Timmerhaus, & West
Plant Design and Economics for Chemical Engineers textbook, (266, Figure 6-14, Cost
tabulation for selected utilities and labor). Since the market price utilized is in the 2001
year value, the estimated cost is bought to present value based on Marshall & Swift cost
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Table 5.11.a – Annual Cost of Utilities
Cooling Water
Stream
[kg/hr]
203 - CWIN 4.00E+06
204 - CWIN 4.80E+06
302 - CWIN 5.70E+05
303 - CWIN 5.50E+05
304 - CWIN 5.70E+05
401 - CWIN 5.50E+05
410 - CWIN 1.80E+05
Total [kg/hr] 1.12E+07
Market Price 0.08 $ / 1000 kg
2001 Price
Cost [$/hr] $898
Cost [$/year] $7,539,840
Present Value (2010) Price
Cost [$/hr] $1,196
Cost [$/year] $10,045,308
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5.12 Operating Labor
The total annual labor cost was calculated from operating costs, supervision
costs, and laboratory charges. The supervision and laboratory expenses are calculated
from a percentage of the operating labor costs. The operating labor expenses were
calculated from the assumption that there are 15 workers per shift, with two twelve hour
shifts a day. The plant is assumed to be running 350 days out of the year with a total
scheduled downtime of 15 days. The cost of one employee per kilogram of ethylene
produced was required to calculate the operating labor expenses. This value was
obtained from chapter three of Plaint Design and Economics for Chemical Engineers
using a ratio of the cost of one employee per kilogram of ethylene produced in 2000
(Peters, Timmerhaus, West Table 3-11). Using that ratio, the amount of ethylene
produced in the textbook plant, and the amount produced in the simulated plant to
obtained the 2010 cost of one employee per kilogram of ethylene produced. Once this
value was calculated, the operating labor costs was determined based on workers per
shift, hours per shift, operating days per year, and ethylene production. The economic
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Table 5.12.a – Economics of Operating Labor
Operating Labor
0.0082 $4,304,311 $45.16 $5,689,889
(15 workers/shift)
Operating Supervision
- $645,647 $50.80 $853,483
(2 supervisors/shift)
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6. SAFETY
Safety is considered a major part of any well-functioning facility. In designing this
plant OSHA guidelines were implemented to ensure that as profits are made employee
important aspect to running an ethylene plant any person entering process areas should
For the protection of the employee, it is required that the following equipment be
Earplugs
Safety glasses
Steel toed shoes
Fire retardant clothing (FRC)
Gloves
Hardhat
Goggles (in required areas)
Radio (to allow for continuous communication)
H2S monitors
Safety harness (in required areas)
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6.1 Personal Protective Equipment (PPE) (cont.)
In case of emergencies the following equipment should be kept near the process area,
Respiratory Pack
Hazmat Suits
Safety Shower
Fire Extinguisher
Fire Blankets
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6.2 HAZOP
A hazardous operations (HAZOP) chart has been included for the major pieces of
equipment to help inform of the possible risks associated with those vessels.
All Material
Other leakage, LEL meters around
Operation than
Flow Pipe fracture
possible plant boundaries
al Areas explosion
Heat exchanger
damage (E-103)
V-102 No Flow (113) BFW valve closed Add flow indicator
and Furnace
Steam damage.
Drums Heat exchanger Add level alarm to
↓ Level Level indicator malfunction
damage (E-103) indicate no level
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and Furnace available.
damage.
Trip furnace. Add drain
More Flow (113) Flow indicator misread Drum overfill
line
Liquid in steam Add Level Alarm and
↓ ↓ ↓
line to furnace possible trip furnace
Table 6.2.a – HAZOP Evaluation of the Process (continued)
Guid
Possible
Equipmen e Propert Action
Possible Cause Consequenc
t Wor y Required
e
Reference d
Heat exchanger
E-103 damage (E-103)
Flow (114) BFW valve closed Add flow indicator
and Furnace
Transfer
No damage.
Line Furnace Damage
Exchangers Pluggage in Line 112 due to Flow Indicator
Flow (112) and possible
Coke trips furnace
↓ explosion
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alarm
Level Indicator and
alarm and increase
↓ ↓ Increase in furnace rates Water in Fuel Oil P-201 flow rate
Level Indicator and
Less Flow Pluggage in line 207 Damage to P-201 alarm
Revers Check Valve on
e Flow Backpressure from Line 210 Tank Rupture line 210
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Add pressure relief
valve, add pressure
More Pressure Too much heat E-205 Vessel Rupture indicator
↓ Flow Pluggage of line 220 Column Flooding Add level alarms
Not enough heating in Add flow indicator,
tower, causing offspec and increase
Less Heat Pluggage on line 219 temperature in line 206 reboiler rate.
No Flow Pluggage line 323 Backflow from 324 Add flow alarm
C-301 more flow from line
Condens More Flow 323 Possible column flooding Add level alarm
ate Add pressure relief
↓ Pressure Pluggage on line 324 Rupture vessel valve to flare
Stripper Tempera increase steam flow Too much material flowing High temperature
↓ ture rate to E-301 in line 324 alarm.
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Pressure fluxuation in Add pressure alarm
↓ Pressure line 307 Damage to CGC and trip CGC
Equipm Guid
ent e Prope Possible
Possible Cause Action Required
Referen Wor rty Consequence
ce d
Valve on line 311 Tank overfill, and possible Add pressure relief
V-303 More Level closes over pressure valve and level alarm
Add low level alarm
Knockout No Level E-304 pluggage Tank runs dry (LLA)
Drums revers Fluid from V-302 Add level alarm, and
e Flow V-303 overfill returning to V-303 relief to flare if overfill
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Equipm Gui
ent de Proper Possible
Possible Cause Action Required
Referen Wor ty Consequence
ce d
S-401 No Flow Pluggage in line 404 Tank runs dry Add level alarm
Water vessel overfill causing
Decanter More Level Line 405 plugs water to enter line 406 Add level alarm
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Table 6.2.a – HAZOP Evaluation of the Process (continued)
Equipm Guid
ent e Proper Possible
Possible Cause Action Required
Referen Wor ty Consequence
ce d
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Table 6.2.a – HAZOP Evaluation of the Process (continued)
Equipm Guid
ent e Proper Possible
Possible Cause Action Required
Referen Wor ty Consequence
ce d
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7. Environmental
This proposed ethylene process has been designed in compliance with EPA
Environmental controls for air quality, water quality, ambient noise level, as well as
emissions and effluents are included. A pollution control system is also recommended
The process has been designed to comply with the U.S. Clean Air Act Amendments. A
list of possible emissions is included along with the environmental release limits.
Majority of the components listed in this table, are emissions from the furnace. Emission
detectors can be put in place around the units themselves and the surrounding
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7.2 Water Quality Control
To perform in compliance with the Clean Water Act, any process water will be sent to
onsite water treatment facility. This facility will purify the water by adding approved
chemicals, such as ferrous chloride, to bring the pH level to normal drinking levels.
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7.3 Noise Level Control
This process has been designed to follow EPA and OSHA noise level standards. The
noise levels which industrial plants produce. In table 7.3.a, is a list of possible
equipment noise sources and there levels, as well as optional control solutions. The
maximum allowable noise level is at 70 dBa for industrial levels. Noise receptors are
Table 7.3.a - Equipment noise sources, levels, and potential control solutions
Sound Level,
dBa, at a
Equipment Possible noise control treatments
distance of
1m
Table 7.3.a is copied from the Peters, Timmerhaus, & West Plant Design and Economics for
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8. Societal Responsibility
The company is dedicated to designing and maintaining a chemical facility that
protects the environment and surrounding communities. To guarantee the plant stays
within regulations, the designing engineers strive to maintain compliance with EPA and
OSHA standards, as well as federal laws. Many controls and alarms have been put in
place to avoid any harmful and hazardous impacts, such as emission detectors and
noise receptors. It is also recommended the facility is placed in an area with minimal
population. Along with regulation compliance, we will strive towards reducing impacts on
the environment and community. Material Safety Data Sheets (MSDS) are continuously
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9. Conclusion
With ethylene products in high demand throughout the petrochemical industry as
Although the process of steam pyrolysis in chapter three of Plant Design and
Economics for Chemical Engineers utilizes a pure propane feed this case study, which
includes only the front-end, has shown that an ethane-propane feed mixture is not only
feasible, but potentially more economical based on market prices of eligible feeds.
Furthermore, this plant required only 90,000 kg/hr of 70/30 wt% EP feed to produce
62,000 kg/hr ethylene in comparison with an ethylene plant that utilized 146,000 kg/hr
pure propane feed. Operational days were set at 350 days a year with 15 days of
scheduled downtime, and the yearly ethylene output was calculated to be 1.2 billion
pounds.
conducted for all parts of the process that were simulated. Standard safety equipment
was needed, along with hydrogen sulfide monitors and radio communication devices.
Emergency equipment such as hazmat suits, safety showers, and fire extinguishers
The major pieces of equipment were sized based off of various parameters, such as
volumetric and mass flowrates, using engineering techniques. Once the equipment had
been sized, a cost was evaluated using the online cost estimator provided by McGraw-
Hill. The FCI was then calculated based on the total equipment prices. Thus, based
on these results
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10. References
http://www.mhhe.com/engcs/chemical/peters/data/ce.html
Detrow, Scott. ‘Ethane Prices Are “Collapsing,” According To The Wall Street Journal.’
StateImpact. 2012.
http://stateimpact.npr.org/pennsylvania/2012/06/27/ethane-prices-are-collapsing-
according-to-the-wall-street-journal/
http://www.green-planet-solar-energy.com/ethene.html
Peters, Timmerhaus, West. Plant Design and Economics for Chemical Engineers. New
http://www.ifc.org/ifcext/enviro.nsf/AttachmentsByTitle/gui_petrochem_WB/$FILE
/petrochm_PPAH.pdf
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11. Appendix
< This section discusses >
Figure 11.1.a: Summary of purchased equipment cost for the ethylene process
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Figure 11.1.c: Cost indexes as annual averages
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11.2 Appendix B: Raw Material Calculations
Figure 11.2.a: Material, utility, and by-product costs for the base-case ethylene
process.
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11.3 Appendix C: Equipment Sizing and Pricing
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Figure 11.3.c - Block E-203
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Figure 11.3.e - Block E-302
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Figure 11.3.g - Block E-304
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Figure 11.3.i - Block E-402
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Figure 11.3.k - Block E-404
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Figure 11.3.m - Block E-409
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Figure 11.3.o - Block K-301
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Figure 11.3.q - Block K-303
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Figure 11.3.s - Block K-401
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Figure 11.3.u - Block V-302
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Figure 11.3.w - Block V-401
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Figure 11.3.y - Block C-201B
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Figure 11.3.aa - Block C-201D
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Figure 11.3.ac - Block C-401 Tray Sizing Specifications
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Temperature C -11.998 12.99997 -11.7738 166.8642
Pressure bar 17.44 17.92 17.44 17.44
Vapor Frac 0.992103 0 1 0
Mole Flow kmol/hr 6810.727 4.676262 6785.219 30.18509
Mass Flow kg/hr 137021.3 363.3102 135028.3 2356.296
Volume Flow cum/hr 7817.605 0.515383 7850.484 4.478359
Enthalpy MMkcal/hr -18.3552 -0.10092 -17.9841 -0.15453
Mass Flow kg/hr
HYDRO-01 4195.66 0.035205 4195.695 1.15E-10
CARBO-01 13.74139 0.000316 13.74171 2.03E-11
CARBO-02 0 0 0 0
HYDRO-02 0 0 0 0
METHA-01 11920.83 0.70565 11921.53 1.35E-06
ACETY-01 367.4671 0.133963 367.6007 0.000339
ETHYL-01 62079.57 15.21373 62094.78 0.007387
ETHAN-01 44197.39 16.08355 44213.4 0.064984
PROPA-01 61.94909 0.10819 60.94819 1.109085
METHY-01 61.89718 0.141564 59.85558 2.183158
PROPY-01 5399.939 6.307319 5393.187 13.05865
PROPA-02 3198.403 4.094084 3188.354 14.14288
1:3-B-01 1938.983 8.558701 1739.871 207.6706
ISOBU-01 273.8914 1.097416 248.8655 26.12329
1-BUT-01 251.1741 1.012272 228.2476 23.93871
N-BUT-01 303.2447 1.336819 276.7398 27.84167
N-PEN-01 823.5419 12.60464 541.2966 294.85
BENZE-01 1107.499 70.9404 309.0544 869.3853
TOLUE-01 170.8787 38.41427 13.5615 195.7315
M-XYL-01 0 0 0 0
N-HEX-01 555.96 29.05791 160.8196 424.1984
N-NON-01 99.25945 157.4642 0.733579 255.99
WATER 0 0 0 0
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Figure 11.3.ae - Block C-402 Configuration
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Temperature C -12.0005 54.21543 -46.5347
Pressure bar 17.44 17.09 17.09
Vapor Frac 0.999975 0 1
Mole Flow kmol/hr 6785.219 262.1674 6523.051
Mass Flow kg/hr 135028.3 12212.15 122816.1
Volume Flow cum/hr 7841.71 26.26394 6469.297
Enthalpy MMkcal/hr -18.0004 -1.50055 -19.2434
Mass Flow kg/hr
HYDRO-01 4195.695 2.43E-31 4195.695
CARBO-01 13.74171 1.47E-26 13.74171
CARBO-02 0 0 0
HYDRO-02 0 0 0
METHA-01 11921.53 4.62E-17 11921.53
ACETY-01 367.6007 1.86E-06 367.6007
ETHYL-01 62094.78 9.82E-07 62094.78
ETHAN-01 44213.4 0.000303 44213.4
PROPA-01 60.94819 60.94791 0.000287
METHY-01 59.85558 59.85558 3.64E-06
PROPY-01 5393.187 5383.915 9.272654
PROPA-02 3188.354 3188.245 0.108942
1:3-B-01 1739.871 1739.871 2.54E-09
ISOBU-01 248.8655 248.8655 7.31E-10
1-BUT-01 228.2476 228.2476 7.62E-10
N-BUT-01 276.7398 276.7398 2.57E-08
N-PEN-01 541.2966 541.2966 3.22E-18
BENZE-01 309.0544 309.0544 1.47E-23
TOLUE-01 13.5615 13.5615 4.91E-34
M-XYL-01 0 0 0
N-HEX-01 160.8196 160.8196 4.07E-29
N-NON-01 0.733579 0.733579 3.04E-52
WATER 0 0 0
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Figure 11.3.ah - Block D-401 Stream Results
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Figure 11.3.aj - Block ETH-RXTR (Furnace) Specifications
Component Yield
HYDRO-01 0.0355
CARBO-01 0.0001
CARBO-02 0.0001
HYDRO-02 0.0001
METHA-01 0.0417
ACETY-01 0.0025
ETHYL-01 0.482
ETHAN-01 0.4
PROPA-01 0.0001
METHY-01 0.0001
PROPY-01 0.0111
PROPA-02 0.0017
1:3-B-01 0.0107
ISOBU-01 0.0011
1-BUT-01 0.001
N-BUT-01 0.0027
N-PEN-01 0.0027
BENZE-01 0.0048
TOLUE-01 0.0006
M-XYL-01 0
N-HEX-01 0.0014
N-NON-01 0
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Figure 11.3.ak - Block PRO-RXTR (Furnace) Specifications
Component Yield
HYDRO-01 0.0129
CARBO-01 0.0001
CARBO-02 0.0001
HYDRO-02 0.0001
METHA-01 0.2467
ACETY-01 0.0033
ETHYL-01 0.345
ETHAN-01 0.044
PROPA-01 0.0017
METHY-01 0.0017
PROPY-01 0.1396
PROPA-02 0.1
1:3-B-01 0.0265
ISOBU-01 0.0052
1-BUT-01 0.0048
N-BUT-01 0.0005
N-PEN-01 0.0181
BENZE-01 0.022
TOLUE-01 0.0048
M-XYL-01 0
N-HEX-01 0.0144
N-NON-01 0.0085
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Figure 11.3.al - Block R-401 Specifications
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Temperature C 79.4 94
Pressure bar 35.77 35.57
Vapor Frac 1 1
Mole Flow kmol/hr 6523.051 6508.935
Mass Flow kg/hr 122816.1 122816.1
Volume Flow cum/hr 5146.556 5416.351
Enthalpy MMkcal/hr -11.4546 -10.981
Mass Flow kg/hr
HYDRO-01 4195.695 4167.238
CARBO-01 13.74171 13.74171
CARBO-02 0 0
HYDRO-02 0 0
METHA-01 11921.53 11921.53
ACETY-01 367.6007 0.03676
ETHYL-01 62094.78 62490.8
ETHAN-01 44213.4 44213.4
PROPA-01 0.000287 0.000287
METHY-01 3.64E-06 3.64E-06
PROPY-01 9.272654 9.272654
PROPA-02 0.108942 0.108942
1:3-B-01 2.54E-09 2.54E-09
ISOBU-01 7.31E-10 7.31E-10
1-BUT-01 7.62E-10 7.62E-10
N-BUT-01 2.57E-08 2.57E-08
N-PEN-01 3.22E-18 0
BENZE-01 1.47E-23 0
TOLUE-01 4.91E-34 0
M-XYL-01 0 0
N-HEX-01 4.07E-29 0
N-NON-01 3.04E-52 0
WATER 0 0
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.
Figure 11.3.am - Stream 201 Cooling Water In/Out
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Figure 11.3.ap - Stream 303 Cooling Water In/Out
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Figure 11.3.as - Stream 410 Cooling Water In/Out
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Figure 11.3.au: Separator Sizing Calculations
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11.4 Appendix D: Operating Utility Costs
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11.6 Appendix F: Chemical MSDS Sheets
1. MSDS of Hydrogen
a. http://avogadro.chem.iastate.edu/MSDS/hydrogen.pdf
5. MSDS of Methane
a. http://www.airgas.com/documents/pdf/001033.pdf
6. MSDS of Acetylene
a. http://www.airgas.com/documents/pdf/001001.pdf
7. MSDS of Ethylene
a. http://www.airgas.com/documents/pdf/001022.pdf
8. MSDS of Ethane
a. http://www.airgas.com/documents/pdf/001024.pdf
9. MSDS of Propadiene/Methylacetylene
a. http://www.airgas.com/documents/pdf/002015.pdf
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13. MSDS of Isobutene
a. http://www.praxair.com/praxair.nsf/AllContent/BF76AB324D14663985256
A8600815172/$File/p4614d.pdf
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