United Arab Emirates University

College of Engineering
Department of Chemical & Petroleum Engineering
Training & Graduation Projects Unit

Project Advisor : Dr.Sulaiman Al-Zuhair

Second Semester 2007/2008



By:
Ahoud Zayed 200223541
Amani Abdulallah 200211357
Fatima Ali 200211773
Salama ALQubaisi 200220453










In Graduation Project I:
The most suitable process was selected
Material and energy balances were prepared.
A preliminary feasibility study was also done.
Design a chemical plant to produce 20000 tonnes per
annum of styrene by the catalytic dehydrogenation of
ethylbenzene (EB). Pure EB is available at the plant site
25
o
C and 1 atm











Project Activities In Graduation Project .II:
Process Modifications
Main Design & Sizing of Equipment
Safety and Environmental Impact
Hazard & Operability Study
Cost and Economical Evaluation
Plant site Location
Conclusions &Recommendations




Styrene monomer is an aromatic hydrocarbon which, under
normal conditions, is a clear, colorless, flammable and toxic
liquid.

Co-product with propylene oxide Dehydrogenation of Ethyl benzene
The capacity of styrene production:

About 13x10
6
tonne/year by dehydrogenation of ethylbenzene
process (more than 90% of the total production).

About 1.2x10
6
tonne/year for the second process.

Ethylbenzene is dehydrogenated to styrene by the following
reaction:
America
Canada
Asia
Europe & Middle
East/Africa China/Japan
Saudi Arabia
Availability and market in
Gulf region
Branch


















Fire Heater
Rectors
Distillation column
Vessels
Heat Exchangers
Pump

Fluid pumping power =(1.67) [Flow (m
3
/min)] [P (bar)]
Flowrate (Stream 19) = 32800 kg/h
Density of fluid = 1000 kg/m
3

P = 28.99 - 1.013 = 27.9 bar
Volumetric flowrate = 0.546 m
3
/min
Fluid pumping power = 25.43 kW
Typical = 0.75
Shaft Power = 25.43/0.75 = 33.9 kW
Type of pump based on head : Head of pump = 285 m.


Centrifugal Pump

Pump choices Centrifugal Pump

By using the following heuristics rules:
The heat transfer in radiant and convective sections equal:
Radiant rate = 37.6 kW/m
2
, convective rate = 12.5 kW/m
2

Duty = 10305.6 (kJ/hr)
Apply the rules:
Area radiant section =137.04 m
2

Area convective section = 412.22 m
2
Total Area = 549.26 m
2



Heater
Air
N.G
Fuel Gas
5
4
5 4

Shell and Tube Heat Exchanger
Heat exchanger length must not exceed 10 m
Shell diameter must not exceed 2 m
Shell mass flow rate: 38890 kg/hr
heating of the chemicals will be achieved by using
superheated.
Temperature of stream 3 must increase to temperature of
stream 8
Fouling is ignored

21
Tube outer diameter
Shell inner diameter
Tube length
Number of tube passes
Material
Number of Baffles
Baffle Spacing

22
Advantages: Very common in the chemical industry
because of its compactness (high H.T. area per unit
H.E. volume).
Counter Flow
Heat transfer for hot and cold stream:


Overall heat transfer coefficient:



Area heat transfer coefficient:
) ( ) (
, , , , , out c in c c p c out h in h ph h
T T c m T T c m q = =
lm
T U
Q
A
A
=
o i i t
o t
h h d
d
U
1
1
,
,
+
=
24

Tube size=3/4
Tube OD = 1.05 in
Tube ID=0.824 in

0
10
20
30
40
5 10 15 20 25 30 35
L
e
n
g
t
h

o
f

H
e
a
t

E
x
c
h
a
n
g
e
r

(
m
)




.





Nominal Shell Size, in
Effect of Shell Size on Length of H.E.
at Different Number of Tubes (3/4'' Sch 40)
Acceptable
design limit
n = 100
n = 150
n = 200
25
Tube size=1
Tube OD = 1.315 in
Tube ID=0.033401 in

0
10
20
30
10 15 20 25 30 35
L
e
n
g
t
h

o
f

H
e
a
t

E
x
c
h
a
n
g
e
r

(
m
)




.





Nominal Shell Size, in
Effect of Shell Size on Length of H.E.
at Different Number of Tubes (1'' Sch 40)
Acceptable
design limit
n = 100
n = 150
n = 200
x n = 250
26
Input Variable Input Value
Number Tubes 100
Tube Passes 2
Tube OD (m) 0.0266
Tube ID (m) 0.0209
Tube Length (m) 0.2101
Paddle of tube (m) 0.2667
Shell ID (m) 0.3332
Baffles No
Shell Flow Rate (kg/s) 32800
Output Variable Output
Value
U (W/m
2
.
o
C) 2040.72
Area (m
2
) 69.33

Heat Transfer Rate
(KW)
3990.66
27


PBR: Is used to describe chemical reactions in continuous,
flowing systems.

Advantages
1. High volumetric unit conversion

2. Run for long periods of time without maintenance

Chemical Reaction Equations:

2 2 5 6 3 2 5 6
H CHCH H C CH CH H C +
4 3 5 6 2 3 2 5 6
CH CH H C H CH CH H C + +
c A
P
RT
r ) 1 /( )
21708
exp 10 24 . 4 (
6
1
u
|
.
|

\
|
=
c C A
P P
RT
r ) 1 /( )
26857
exp 1723 (
2
u
|
.
|

\
|
=
29

|
.
|

\
|
|
|
.
|

\
|
|
|
.
|

\
|
=
T
T
P
P
F
F F
C
o
o T
A
o
To
A
u
T R C P
A A 1
=
T R C P
C C 1
=
|
.
|

\
|
|
|
.
|

\
|
|
|
.
|

\
|
=
T
T
P
P
F
F F
C
o
o T
C
o
To
C
u
30
Design equation
Species A
Species B
Species C
Species D
Species E
'
A
i
r
dW
dF
=
A A A
A
r r r
dW
dF
2 1
'
= =
A A B
B
r r r
dW
dF
2 1
'
+ = =
A C
C
r r
dW
dF
1
'
= =
A D
D
r r
dW
dF
1
'
= =
A E
E
r r
dW
dF
2
'
= =


31


( )( ) ( )( )

A + A
=
i i
RX A RX A
Cp F
T H r T H r
dW
dT
) ( ) (
2 2 1
1
|
|
.
|

\
|
|
|
.
|

\
|
|
|
.
|

\
|
o
=
To
T
o
o
o
F
F
P P
P
T
T
2 dW
dP


Reactors Diameter
(m)
Height /length
(m)
Volume
(m
3
)
R-100 5.10 15.3 312.2
R-101 3.6 11.06 118.3
5 . 0
]
) (
[ max
v
V L
K V

=

V
max
= maximum allowable vapor velocity, m/sec.

L
= liquid density, kg/m
3.

v
= vapor density, kg/m
3.

k = 0.0305 m/s.
A V Q * =

Q : [vapor flow rate, in m3/s].
V :[vapor velocity in m/s].
Then the drum diameter can calculated (D) in m = [4 A / ]
0.5
.
(H): which is the drum height in m = [4 V / D
2
]

Diameter (m) 0.45
Height /length
(m)
2.25
Volume (m
3
) 0.35
Vertical Separator

From the following equation, the volume of the flash distillation will be equaled
to;









V is Volume of the tank (m
3
),
D is Diameter of the tank ( m),
H: Height of the tank (m),
F is mass flow rate( kg/hr)

avg
is density average of the flow rate ( kg/m
3
).

4
) . . (
) (
2
3
H D
m V
t
=
3D H Since,
m 32 . 2 12.49
3600 3
F 10 4
3
V 4
) m ( D
: diameter the Tofind
3
3 3
=
= =
t

=
t
=
Diameter (m) 2.32
Height /length
(m)
6.96
Volume (m
3
) 29.42
Horizontal Separator
Feed Stream 14: Total Mole flow rate 79.63(kmol/hr)
Distilled, D, Stream 15: Mole flow rate for Light Key,LK LK = 8.80 (kmol/hr) for Toluene
Reboiler, W), Stream 16) Total Mole flow rate for Heavy Key HK =36.03(kmol/hr).
Distilled, D, Stream 15:Total Mole flow rate for Light Key, LK = 43.6 (kmol/hr
Reboiler, W, Stream 16: Mole flow rate for Heavy Key, HK = 22.06 (kmol/hr). for Styrene

To find the Mole fraction
Feed Stream 14: Total Mole flow rate 79.63(kmol/hr)
Distilled, D, Stream 15: Mole flow rate for Light Key,LK LK = 8.80 (kmol/hr) for Toluene
Reboiler, W), Stream 16) Total Mole flow rate for Heavy Key HK =36.03(kmol/hr).
Distilled, D, Stream 15:Total Mole flow rate for Light Key, LK = 43.6 (kmol/hr
Reboiler, W, Stream 16: Mole flow rate for Heavy Key, HK = 22.06 (kmol/hr). for Styrene

rat e f l ow mol e Tot al
rat e f l ow Mol e
X
i
=
0. 33
) (
WH
X
WL
X

DH
X
DL
X

FH
X
FL
X

H
X
L
X
Vol at i l i t y Rel at i ve
bot t op f eed avr eage
bot
t op
f eed
=
=
=
=
=
Comp. x
F
F
Pv
(kPa) k

feed x
D
D
Pv
(kPa) k

top x
W
W
Pv
(kPa) k

botto
m

average
LK Toluene 0.11 9.07 4.87 4.26 4.26 0.201 8.80 2237.4 1.98 1.98 0.007 0.27 146.2 2.62 2.62 2.81
HK Styrene 0.31 24.6 1.14 1.00 1.00 0.06 2.60 1129.9 1.00 1.00 0.61 22.0 55.76 1.00 1.00 1.00
Ethyl
benzene 0.29 23.6 1.69 1.48 1.48 0.23 9.95 1394.87 1.23 1.23 0.38
13.7
4 72.01 1.29 1.29 1.33
Hydrogen 0.16 13.3 0.0 0.0 0.0 0.31 13.3 0.0 0.0 0.0 0.0 0.0 0.00 0.00 0.00 0.00
Methane 0.11 8.80 5300 4643 4643 0.20 8.80 522800 462 462 0.0 0.0 28226 506 5063 10284
Ethane 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Water 0.02 0.15 4.24 3.72 3.72 0.0 0.15 5549.82 4.91 4.91 0.0 0.0
224.6
1 4.03 4.03 4.19
O2 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
CO2 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Total 1.0 79.6
5301
7 - - 1.00 43.6 - - - 1.00 36 - - - -

Nmin = 5.43
Assuming = 1.172
Until (i*xi
F
)/(i-) = 1.00
1-q =Rmin 1.11
q = (i*xi
D
)/(i-) = 2.11
1+Rmin= R 1.34

(R - Rmin)/(R + 1) =
Using this value in
Gilliland correlation
chart 0.10
37
Where:
= vaporization fraction
xi
F :
mole feed fraction
R
min
: minimum reflux ratio
R: optimum reflux ratio

tray
: Efficiency
Nmin: Minmum Number of trays



avr
LW
HW
HD
LD
X
X
X
X
N
o ln
ln
min
(

=

To determine minimum number of trays N
min
is found with Fenske- Underwood
Equation

10 . 0
1
) 5 . 1 2 . 1 ( :
1
min
min
min
=
+

u
= +

R
R R
R R
X
R
iD i
o
o
59 . 0
1
min
=
+

N
N N
N ,theoretical 14.68
Take
tray
0.6
N, actual 24.46
Results of trays:
Gilliland correlation chart

Tower Diameter, D (m) 0.33
Tower Height,H (m) 17.68
Volume ,V (m
3
) 1.51
Reflux Ratio ,R 1.34
Number of Trays ,N
theoretical
14.68
Number of Trays ,N
actual
24
Pressure drop, P
tower
,bar 0.17
Tower Diameter (m) 0.83
Tower Height, m 22.88
Volume ,V (m
3
) 12.4
Reflux Ratio ,R 4.17
Number of Trays ,N
theoretical
19.88
Number of Trays ,N
actual
33
Pressure drop, P
tower
,bar 0.14





With reliable equipment, air quality should be regularly monitored to insure
that contaminants remain at a safe level.


Employees should be educated in the appropriate response should a spill
or leakage occur.

Care should be taken in storage of flammable
substances.



By making energy efficiency, one can decrease the amount of fuel
consumed by focus in the design of the styrene production plant.

Another way to help compensate for the environmental damage due
to carbon dioxide emissions is the implementation of carbon sinks.

Plants and trees which consume carbon dioxide as a part of their
metabolic cycle are examples of natural carbon sinks to reduce
the effect of greenhouse gases until a permanent solution is found.
















Is a systematic qualitative technique to identify process hazards
and potential operating problems using a series of guide words to
study process deviations .

A HAZOP is used
1. To question every part of the process
2. To discover what deviations from the intention of the design
can occur and what their causes and consequences may be.

Causes of Deviations :

There are three basic types of causes :

Human error, Equipment failure External Events

















Guide-word Meaning
No
(not, none)
None of the design intent is achieved
More
(more of, higher)
Quantitative increase in a parameter
Less
(less of, lower)
Quantitative decrease in a parameter
As well as
(more than)
An additional activity occurs
Part of Only some of the design intention is achieved
Reverse Logical opposite of the design intention occurs
Other than
(other)
Complete substitution - another activity takes place
Early / late The timing is different from the intention
Before / after The step (or part of it) is effected out of sequence
Faster / slower The step is done/not done with the right timing
Where else Applicable for flows, transfer, sources and destinations









The equipment module costing technique is a common
technique to estimate the capital cost of new chemical
plant
Direct project expenses include:
equipment cost
materials required for installation
labor to install equipment and material






The equipment module costing technique is a common
technique to estimate the capital cost of new chemical plant
Direct project expenses include:
equipment cost
materials required for installation
labor to install equipment and material






1- To calculate bar modulte cost (C
BM
) first should be found :
purchased cost using the following equation

Where Ki is constant value and X is the capacity or size
parameter for the equipment

| |
2
10 3 10 2 1 10
) ( log ) ( log log X K X K K C
o
P
+ + =






2- bar module cost factor using the following equation:

Where B is constant value and FM can get it from following Figure








Pressure factor for vessel can be calculated by


And for other equipment


3- Calculate bar module cost

( )
( ) | |
0063 . 0
00315 . 0
1 6 . 0 850 2
1
.
+
+
+
=
P
D P
F
vessel P
| |
2
10 3 10 2 1 10
) ( log ) ( log P C P C C F Log
P
+ + =
BM
o
P BM
F C C =







Bar module cost for flash drum
| |
2
10 3 10 2 1 10
) ( log ) ( log log X K X K K C
o
P
+ + =
V-101 Equipment
Horizontal Orientation
2.32 D (m)
6.96 L (m)
0.8 P (bar)
CS MOC
29.64 V (m3)
3.5565 K1
0.3776 K2
0.0905 K3
C
P
o
= $ 20,339.61
2.25 B1
1.82 B2
( )
( ) | |
0063 . 0
00315 . 0
1 6 . 0 850 2
1
.
+
+
+
=
P
D P
F
vessel P
Log C
p
o
= 3.5565 + 0.3776 log ( 29.64(+ 0.0905*[log (29.64)]
2

F
P
= 0.89






( )
M P BM
F F B B F
2 1
+ =
F
BM
= 3.87
For operating pressure= 0.8 bar,
8904 . 0 =
P
F
1 =
M
F
BM
o
P BM
F C C =
CBM= $ 78,725.49








CGR 2008=
$ 10,770,000

=
+ =
n
i
i BM
o
TM GR
C C C
1
, 50 . 0
Equipment CBMo ($) CBM($)
Heat Exchangers :
E-100 63,000 121,000
E-101 73,000 67,000
E-102 113,000 104,000
E-103 57,000 57,000
E-104 88,000 81,000
E-105 93,000 93,000
Pump 22,000 34,000
Distillation Column 1 552,000 1,533,000
Distillation Column 2 1,070,000 2,919,000
Decanter 84,000 79,000
Flush Drum 8,000 7,000
Reactor 1 468,000 1,113,000
Reactor 2 159,000 311,000
Sum 2,850,000 6,519,000






Total Cost ($/yr) Cost ($/GJ) Duty (GJ/hr) Duty (KJ/hr)
Used Utility
Service Equipment
731,000 2.1 4.21E+01 42061897.26 hps E-100
172,000 0.16 1.28E+02 128176603.7 Cw E-101
4,000 0.16 2.77E+00 2769752.331 Cw E-102
71,000 2.4 3.54E+00 3.54E+06 lps E-103
48,000 0.16 3.57E+01 35718330.5 Cw E-104
719,000 2.4 3.57E+01 3.57E+07 lps E-105
The cost of utility was found to be $ 1,743,000

Also the natural gas used as a utility. The cost of natural gas was found to be 156,000 $/yr.

The total cost of row material is found to be 1,899,000 $ /yr






14,000 $/yr Waste Water
11,413,000$/yr Row material
1,899,000$/yr Utility cost
916,000 $/yr Labor cost
21,909,000$/yr Cost of manufacturing
) C C C ( 23 . 1 C 73 . 2 FCI 280 . 0 COM
RM WT UT OL
+ + + + =







Break even
-6000000
-4000000
-2000000
0
2000000
4000000
6000000
0 5000 10000 15000 20000 25000
Product (ton)
n
e
t

c
o
s
t
(Break even Point)







(Break even Point)






The cost for styrene and toluene was found to be 1.03 $ /kg.
The annual cost for styrene was found 24,795,000 $ /yr .
Profit before taxes = income COM
The profit is found to be 2.88 million





The main principle factors that must be considered when
selecting a suitable plant site:

1. Location, with respect to the marketing area
2. Raw material supply
3. Transport facilities
4. Availability of labor
5. Availability of suitable land
6. Environmental impact and effluent disposal
7. Local community consideration
8. Climate
9. Political and strategic consideration


The principal factors to be considered are:
1. Economic consideration: construction and operation cost.
2. The process requirement
3. Convenience of operation
4. convenience of maintenance
5. Safety
6. Future expansion
7. Modular construction









The capital cost of the plant has reached $10,770,0000.
The operating cost has reached $ 21,909,000
The yearly profit for the plant after starting the production is about $2.88millions.
The profit will be start with interest after 4 years.
Based to these studies on this project it was recommended that to create a plant
for styrene production in the United Arab Emirates, to be one of the countries that
export the styrene not just imports from other countries.