Plant Layout Ayos PDF

7/23/2019 Plant Layout Ayos PDF

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CHAPTER I

INTRODUCTION

The petrochemical industry is a substantial contributor to the worlds

economic development. Petrochemicals connect the upstream oil and gas industry

to the downstream sectors such as energy, material, agricultural and industrial

sectors. It is a vital part of human life, and it is hard to imagine modern existence

without these products.

Naphtha, as a versatile feedstock, is considered to be the building block of

the petrochemical industry. One of the main products from the processing of

naphtha reformate are aromatics. Aromatics products are composed of benzene,

toluene and xylenes (BTX). BTX is considered as the primary petrochemicals

since they can be transformed into other finished petrochemical derivatives. BTX is

used to make a wide variety of products including plastics, resins, synthetic fibers,

rubber lubricants, dyes, detergents, drugs and pesticides.

This makes the global consumption of benzene, estimated at more than

40,000,000 tons in 2010, showed an unprecedented growth of more than

3,000,000 tons from the level seen in 2009. Likewise, the xylene consumption

showed unprecedented growth in 2010, growing by 2,800,000 tons, and a full ten

percent growth from 2009. (ChemSystems, 2011)

The accelerating economic and industrial growth of the ASEAN member

countries develops also an increase in demand of benzene, toluene and xylenes.

The projected BTX demand in the ASEAN Region is 103,420 metric tons by 2025


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based from the United Nation Trade Commondity Statistics Database. There exist

a gap wherein the supply certainly cannot meet the demand in the ASEAN region.

Although eight manufacturing plants were identified on target market locations

producing BTX separately, the demand is still unsatisfied due its huge amount and

wide area of customers.

In line with this condition, the proponents are proposing a benzene, toluene

and xylenes manufacturing plant which will have a desired output to equally meet

the demand for BTX in the ASEAN region. The proposed BTX manufacturing plant

will process naphtha reformate into benzene, toluene and xylenes.

The proposed manufacturing plant will be strategically located in (7

6'4.32"S 11236'49.09"E) Manyar, Gresik Regency, East Java, Indonesia. One of

the reason is that East Java is considered to have the most attractive hourly wage

in Asia. This means that production costs are lower and thus, manufacturer profits

are higher. In terms of feedstock availability and accessibility, the target location is

70 kilometers from Tuban petrochemical plant which will be the primary supplier of

naphtha reformate feedstock. Tuban petrochemical plant has a rated output

capacity of 1 million metric tons of naphtha per year, a sufficient value to supply

the meet the required feedstock. Backup suppliers are PetroChina Dalian Refinery,

Liaoning, China and Ganga Rasayanie Pvt. Ltd., South India. Reserve supplier is

Petron Bataan Refinery, Philippines.The target location has sufficient manpower

and utilities to meet the requirements of the plant.

The target market of proposed plant are the ASEAN member countries

specifically Singapore, Cambodia, Indonesia and Vietnam. These four countries


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were evaluated to have higher BTX import over export which indicates that these

countries have high demand for BTX. Singapore is the primary costumer for

benzene. Cambodia, Indonesia and Vietnam are the target consumers for toluene.

Cambodia and Indonesia are the target customer for xylenes.

The plant will continue to meet the demands for benzene, toluene and

xylenes of different countries of the target customers. The plant location is 1900

kilometers away from Singapore, 4700 kilometers from Vietnam and 4300

kilometers from Cambodia. These values indicate the efficient transportation of

BTX products to the target customers.


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Figure 1. Target Location Aerial View

Figure 2. Target Location (2 km elevation)


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CHAPTER II

DESIGN OBJECTIVES

The main objective of the project proposal is to scientifically design a

Benzene, Toluene and Xylene (BTX) Manufacturing Plant with a desired output

capacity of 104,300 metric tons (MT) of BTX per annum.

Furthermore, the project proposal also targets to undertake the following

specific objectives taking into consideration technical, in order to achieve a realistic

technical, economic and environmental plant design.

1. To formulate three (3) design options for the Benzene, Toluene and

Xylene (BTX) Manufacturing Plant taking into consideration the following multiple

realistic constraints:

1.1 Technical Efficiency

1.2 Economic Feasibility

1.3 Environment Sustainability

2. To design the technical aspects of the plant taking into consideration the

following:

2.1 Plant Lay-out

2.2 Process Flow Diagram

2.3 Equipment Specification

2.4 Mass and Energy Balances

2.5 Required Capacity

2.6 Over-all Plant Efficiency

2.7 Technical Standards and Catalogues


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3. To design the economic analyses of the plant taking into consideration

the following:

3.1 Net Present Value

3.2 Payback Period

3.3 Rate of Return

3.4 Sensitivity Analysis

4. To prepare environmental management of the plant taking into

consideration the following:

4.1 Environment Base Line data

4.2 Health and Safety

4.3 Environmental Impact Assessment

4.4 Monitoring

5. To evaluate and choose the best plant design option using Pareto

optimum method.

6. To develop the project construction execution plan of the plant.

7. To formulate the corresponding summary, conclusions and

recommendations.


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CHAPTER III

TECHNICAL ASPECT

This chapter includes the calculation and preparation of the process flow

diagram, complete plant lay-out, equipment description and specifications, mass

balance and energy balance, required capacity and plant efficiency. Standards

were used to come up with a technically viable design. Technical catalogues were

used to carefully identify the design specifications of each equipment.

A. Design Option I

1. Process Description

Figure 3. Design Option I Process Flow Diagram

On this proposed design, reformate naphtha will pass through the solvent

extraction column to separate non-aromatics component to aromatic component.


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Non-aromatics component along with the extracting solvent from naphtha will go to

raffinate stripping column to separate solvent then the solvent that was recovered

will be feed again to the extraction column while non-aromatics component will go

directly to the storage tank. On the other hand, aromatics components will pass

through the solvent recovery to remove solvent and improve the quality of

aromatics products. After this process, nearly pure aromatics will go through the

clay treater column to further remove present surface reactants. After all these

processes, aromatics will pass through the fractionation column to separate

Benzene, Toluene and Xylene by using the concept of difference in boiling point.

2. Plant Lay-out

Figure 4. Plant top view

Legend:

1Area for Expansion

2Process Area

3Fire Fighting Unit

4Control Room

5Power Generation Unit

6Laboratory

7Plant Utilities

8Waste Water Treatment

9Emergency Water Storage

10Workshop

11Area for Expansion

12Parking Area/Evacuation Area

13Change Room

14Canteen

15Administration Building16Security

17Material Recovery Facility


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Figure 5. Plant Side View

3. Equipment Description and Specification

Specification Sheet No. 1

FEED SURGE DRUM

Height 6.10m

Diameter 5.50m

Orientation Vertical

Pressure 15 psi

Temperature 350C

Materials of Construction Carbon Steel Plates

Capacity 5000 gallons


PUMP 1

Flow 90 gpm120 gpm

Type Centrifugal

Discharge Pressure 30psi

Temperature 50C

Seal Type Single mechanical seal

Driver Type Standard motor

Material Carbon Steel


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PACKED BED EXTRACTION COLUMN

Height 17m

Diameter 0.93m

Pressure 120psTemperature 200C

Number and Type of Trays 3 beds with four stages

Materials of Constructions Carbon Steel Plates


STRIPPING COLUMN

Height 14m

Diameter .80m

Temperature 56C

Pressure 5.12 psi

Application Distillation

Tray Type Sieve

Number of Trays 34

Tray Spacing 0.6096 m

Tray thickness 4.572x10-3m

Tray Material Low and intermediate strength carbon

steel plates for pressure vesselsMaterial of Construction Carbon Steel Plates


STORAGE VESSEL 1

Height 4.00 m

Diameter 2.50 m


Pressure 50psTemperature 200C




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COOLER 1

Type Liquid-LiquidProcess DistillationTemperature 25 CPressure 15 psiArea 1000ft2

Shell

Material Carbon SteelLength 1.95mInside Diameter 0.1625mIncoming pipediameter

in, schedule 40 stainless steel

Outlet pipe diameter 1 in, schedule 40 stainless steel

Tubes

Number of Tubes 28Number of Passes 2, U-bend configurationMaterial Copper, Schedule 40Length 1.905mInside Diameter 0.015875mOutside Diameter 0.01905mPitch 7/8 in, triangular pitchIncoming pipediameter

1 in, schedule stainless steel

Outlet pipe diameter 1 in, schedule stainless steelBaffling Number of Baffles 2

Baffle spacing 1 in. schedule 40 stainless steel


PUMP 2

Flow 90 gpm120 gpm

Type Rotary

Pressure 30psi

Temperature 20C

Material Cast iron


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PUMP 3

Flow 90 gpm120 gpm

Type Rotary

Pressure 30psiTemperature 20C

Material Cast iron


HEATER 1

Type Liquid-Liquid

Process Distillation

Temperature 350 C

Pressure 15 psi

Material Low and intermediate strength carbon steel

plates

Area 1000ft2

Shell


Length 2.1m

Inside Diameter 0.175m

Incoming pipe

diameter



Tubes

Number of Tubes 28

Number of Passes 2, U-bend configuration

Material Copper, Schedule 40

Length 1.905m


Outside Diameter 0.01905m

Pitch 7/8 in, triangular pitch

Incoming pipe

diameter


Outlet pipe diameter 1 in, schedule stainless steel

Baffling Number of Baffles 2



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PUMP 4

Flow 230 gpm

Type Rotary

Discharge Pressure 30psiTemperature 20C

Material cast iron


PUMP 5

Flow 90 gpm120 gpm

Type Centrifugal


Temperature 50C





SOLVENT RECOVERY COLUMN

Height 14m

Diameter 3m

Temperature 38C

Pressure 10 psi

Application Distillation

Tray Type Sieve

Number of Trays 33

Tray Spacing .45m

Tray thickness 4.75x10-3m

Tray Material Low and intermediate strength carbonsteel plates for pressure vessels

Material of Construction Stainless steel


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COOLER 2

Type Liquid-Liquid


Temperature 25 CPressure 15 psi

Material Low and intermediate strength carbon

steel plates

Area 1000ft2

Shell


Length 1.95m


Incoming pipe diameter in, schedule 40 stainless steel


Tubes

Number of Tubes 28



Length 1.905m




Incoming pipe diameter 1 in, schedule stainless steel


Baffling

Number of Baffles 2



STORAGE VESSEL 2

Height 5.50m

Diameter 5.00m

Orientation Horizontal

Pressure 15psi

Temperature 290C




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PUMP 6

Flow 60gpm

Type Rotary

Pressure 30psiTemperature 20C

Material Cast iron

Speed 1800rpm

Power 25-20 hp


PUMP 7

Flow 60gpm

Type Rotary

Pressure 30psi

Temperature 20C

Material Cast iron

Speed 1800rpm

Power 25-20 hp


PUMP 8

Flow 75gpm

Type Centrifugal


Temperature 50


Driver Type Standard motorMaterial Carbon Steel


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HEATER 2

Type Liquid-Liquid


Temperature 350CPressure 15 psi

Material Low and intermediate strength carbon steel

plates

Area 1000ft2

Shell Material Carbon Steel

Length 2.1m


Incoming pipe

diameter



Tubes

Number of Tubes 28



Length 1.905m




Incoming pipe

diameter






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HEATER 3

Type Liquid-Liquid


Temperature 350 CPressure 15 psi


steel plates

Area 1000ft2

Shell


Length 2.1m




Tubes

Number of Tubes 28



Length 1.905m






Baffling

Number of Baffles 2



CARTRIDGE 1

Height 7.6 m

Diameter 1.2 m

Pressure 15 psi

Temperature 425C

Materials of Constructions Welded Carbon steels


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CARTRIDGE 2

Height 7.6 m

Diameter 1.2m

Pressure 15 psiTemperature 425C

Materials of Constructions Welded Carbon steels


BENZENE COLUMN

Height 17m

Diameter 0.93m

Pressure 15 psi

Temperature 100C



Type Packed bed column


STORAGE VESSEL 3

Height 3.70m

Diameter 2.50m


Pressure 15 psi

Temperature 100C




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COOLER 2

Type Liquid-LiquidProcess Distillation

Temperature 25 C

Pressure 15 psi

Material Low and intermediate strength

carbon steel plates

Area 1000ft2

Shell


Length 1.95m




Tubes

Number of Tubes 28



Length 1.905m

Inside Diameter 0.015875mOutside Diameter 0.01905m







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PUMP 9

Flow 70gpm

Type Centrifugal



Driver Type Standard Motor



REBOILER 1

Type Liquid-Liquid

Process DistillationTemperature 350 C

Pressure 15 psi


steel plates

Area 1000ft2

Shell


Length 1.905m




Tubes

Number of Tubes 28



Length 1.905m


Outside Diameter 0.01905mPitch 7/8 in, triangular pitch






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PUMP 10

Height 55gpm

Diameter CentrifugalPressure 5psi

Temperature 50C

Number and Type of Trays Single mechanical seal

Materials of Constructions Standard Motor

Type Carbon Steel


TOLUENE COLUMN

Height 20m

Diameter 1.039m

Pressure 15psi

Temperature 125C





STORAGE VESSEL 4

Height 5.20m

Diameter 4.6m


Pressure 15 psi

Temperature 125C

Materials of Construction Carbon Steel PlatesCapacity 3000 gallons


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COOLER 4

Type Liquid-Liquid

Process DistillationTemperature 25 C

Pressure 15 psi


steel plates

Area 1000ft2

Shell


Length 1.95m


Incoming pipe diameter in, schedule 40 stainless steelOutlet pipe diameter 1 in, schedule 40 stainless steel

Tubes

Number of Tubes 28



Length 1.905m






Baffling

Number of Baffles 2



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PUMP 11

Flow 50gpm

Type Centrifugal






PUMP 12

Flow 60gpm

Type Centrifugal


Temperature 50C





XYLENE COLUMN

Height 18m

Diameter 0.98m

Pressure 15 psi

Temperature 160C





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REBOILER 2

Type Liquid-Liquid


Temperature 350CPressure 15 psi


steel plates

Area 1000ft2

Shell


Length 1.905m




Tubes

Number of Tubes 28



Length 1.905m






Baffling

Number of Baffles 2



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COOLER 5Type Liquid-LiquidProcess Distillation

Temperature 25 CPressure 15 psiMaterial Low and intermediate strength carbon

steel platesArea 1000ft2

Shell

Material Carbon SteelLength 1.95mInside Diameter 0.1625mIncoming pipe diameter in, schedule 40 stainless steelOutlet pipe diameter 1 in, schedule 40 stainless steel

Tubes

Number of Tubes 28Number of Passes 2, U-bend configuration


Length 1.905mInside Diameter 0.015875mOutside Diameter 0.01905mPitch 7/8 in, triangular pitch



BafflingNumber of Baffles 2Baffle spacing 1 in. schedule 40 stainless steel


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STORAGE VESSEL 5

Height 3.40m

Diameter 2.20m

Orientation VerticalPressure 15 psi

Temperature 160




PUMP 13

Flow 10gpm

Type Centrifugal

Discharge Pressure 0.4931psi

Temperature 50C




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REBOILER 3

Type Liquid-Liquid


Temperature 350C

Pressure 15 psi


steel plates

Area 1000ft2

Shell


Length 1.905m




Tubes

Number of Tubes 28



Length 1.905mInside Diameter 0.015875m





Baffling

Number of Baffles 2



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Specification Sheet No. 38COOLER 6

Type Liquid-Liquid


Temperature 25 C

Pressure 15 psi


steel plates

Area 1000ft2

Shell


Length 1.95m




Tubes

Number of Tubes 28



Length 1.905m








Specification Sheet No. 39STORAGE VESSEL

Height .70m

Diameter .50mOrientation Vertical

Pressure 15 psi

Temperature 160C


Capacity 1 gallon


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D. Material Balance

Assumptions:

1. All flow rates are steady.

2. Feed solvent and extracting solvent are immiscible.

3. Extracting solvent concentration remains constant.

4. All gases behave ideally.

5. No chemical reaction occurs during liquid-liquid extraction and extractive

distillation.

Figure 6. Liquid-liquid extraction section

Feed = 17,000 kg/Hr

The amount of naphtha reformate was based from the production of Tuban

Petrochemicals (133.92 MMkg per year).

Tetraethylene Glycol (TEG) = 58,571 kg/Hr

The amount of solvent was based from Environmental Protection Agency (EPA)

reference amount for Tetraethylene Glycol (TEG) used for aromatics extraction

solvent.


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a. Pump 1

M1= M2

M1= 17,000 Kg/Hr

M2= 17,000 Kg/Hr

b. Extraction Column

Raffinate Recovery = 36%

Feed + Lean Solvent = Raffinate + Rich Solvent

M2+ M3= M4+ M5

17,000 Kg/Hr + 58,571 Kg/Hr = 0.36 (17,000 Kg/Hr) + M5

Rich Solvent = 69,451 Kg/Hr

M5= 69,451 Kg/Hr

Raffinate = 6,300 Kg/Hr

M4 = 6,120 Kg/Hr

c. Stripper Column

Efficiency = 97%: Heuristics

Basis: Solvent-To-Extract Ratio = 2

M4 = M7 + M8

Rich Solvent = Extract + Solvent

Rich Solvent = 69,451 Kg/Hr

M8= 2(M7)

69,451 Kg/Hr = M7 + M8


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M7= 23,150.33 Kg/Hr

M8= 46,300.67 Kg/Hr (0.97)

M8 = 44,911.65 Kg/Hr

d. Condenser 1

M9= M7

M7= 23,150.33 Kg/Hr

M9= 23,150.33 Kg/Hr

e. Vessel 1

M9= M10

M10= 23,150.33 Kg/Hr

f. Pump 2

M10= M11

M11= 23,150.33 Kg/Hr

g. Pump 3

M12= M13

M12= 23,150.33 Kg/Hr


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h. Pump 4

M8= M14

M11= 23,150.33 Kg/Hr

i. Pump 5

M5= M15

M11= 69,451 Kg/Hr

j. Solvent Recovery Column

Efficiency = 95 %: Heuristics

Extract = 23,150.33 Kg/Hr

M15 = 69,451 Kg/Hr

Extract = Lean Solvent + Aromatics

M15 = M16 + M17

69,451 Kg/Hr = 0.95(58,571)+ M17

M17= 13,808.55 Kg/Hr

Figure 7. Fractionation Section


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BTX Extract = 13,808.55 Kg/Hr

a. Pump 6

M17= M18

M18= 13,808.55 Kg/Hr

b. Heater 1

M18= M19

M19= 13,808.55 Kg/Hr

c. Clay Treater


M20=13,808.55 Kg/Hr

M21= 13, 670.4645 Kg/Hr

d. Benzene Column


M21= M22+ M23

Aromatics = 16.12% Benzene

M22= M21 (93%) (16.12%)

M22= (13,670.4645 Kg/Hr) (0.93) (0.1612)

M22= 2,049.4214 Kg/Hr

M23= M21M22


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M23=13,670.4645 Kg/Hr2,049.4214 Kg/Hr

M23= 11,621.0431 Kg/Hr

Toluene Column Feed = 11,621.04314 Kg/Hr

e. Condenser 2

M22= M24

M22= 2,049.4214 Kg/Hr

M24= 2,049.4214 Kg/Hr

Benzene Product = 2,049.4214 Kg/Hr

f. Pump 7

M25= M23

M23 =11,621.04314 Kg/Hr

M25=11, 621.04314 Kg/Hr

g. Toluene Column



M25= M26+ M27

M26= (M21) (93%) (72.52%)

M26= (13,670.4645Kg/Hr) (0.93) (0.7252)

M26= 9,219.85 Kg/Hr


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M27= M25M26

M27= 11, 621.04314 Kg/Hr9,219.85 Kg/Hr

M27= 2,401.1931 Kg/Hr

Xylene Column Feed = 2,401.1931 Kg/Hr

h. Condenser 3

M28= M26

M26= 9,219.85 Kg/Hr

M28= 9,219.85 Kg/Hr

Toluene Product = 9,219.85 Kg/Hr

i. Pump 8

M29= M27

M27 = 2,401.1931 Kg/Hr

M29 = 2,401.1931 Kg/Hr

j. Xylene Column



M29= M31 + M30


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M29= 2,401.1931 Kg/Hr

M30= (M21) (93%) (11.36%)

M30= (13,670.4645 Kg/Hr) (0.93) (0.1136)

M30= 1,444.2572 Kg/Hr

M31= M29M30

M31= 2,401.1931 Kg/Hr1,444.2572 Kg/Hr

M31= 956.9359 Kg/Hr

k. Condenser 4

M30= M32

M30= 1,444.2572 Kg/Hr

Xylene Product = 1,444.2572 Kg/Hr

l. Condenser 5

M33= M31

M31= 956.9359 Kg/Hr

M18 = 956.9359 Kg/Hr

C9+Aromatics Product = 956.9359 Kg/Hr


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Table 1. Summary of in-flow rates and out-flow rates in kg/hr

Equipment In-Flow Rate (kg/hr) Out-Flow Rate (kg/hr)

Pump 1 17,000

Extractor 69,451Stripper 69,451

Condenser 1 23,150.33

Vessel 1 23,150.33

Pump 2 23,150.33

Pump 3 23,150.33

Pump 4 23,150.33

Pump 5 69,451

Recovery Column 23,150.33 13,808.55

Pump 6 13,808.55

Heater 1 13,808.55

Clay Treater 13,808.55 13,670.4645

Distillation Column 13,670.4645 2,049.4214


Pump 7 11,621.04314



Pump 8 2,401.1931



Condenser 5 956.9359

Benzene Product 2,049.4214 kg/hr

Toluene Product 9,219.85 kg/hr

Mixed Xylene Product 1,444.2572 kg/hr

BTX Product 12,713.5286 kg/hr


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Production per hour = 12,713.5286 kg/hr

Production per year = (12,713.5286kg/hr) (24 hrs/day) (355 stream days/year)

Production per year = 108,319,263.7 kg/year

E. Energy balance

This section contains the calculations for energy requirements of heat transfer

equipment used in the BTX Manufacturing Plant.

1. Heating Equipments

a. Stripper Column

Mass of incoming aromatics:23,267 kg/hr

Specific heat of aromatics:1.825 kj/kgoc

Temperature of incoming aromatics:200oc

Temperature of leaving aromatics:56 oc

Mass of incoming solvent:45, 118.58 kg/hr

Specific heat of solvent:1.997103 kj/g c

Temperature of incoming solvent:200 oc

Temperature of leaving solvent:56 oc

Specific heat of seawater:3.985 kj/kgoc

Temperature of incoming cooling water:17 oc

Temperature of leaving cooling water:30 oc

[mCp(T2-T1)]AROMATICS+ [mCp(T2-T1)]SOLVENT= [mCp(T2-T1)]CW


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Rich Solvent (TEG) = 58,571 Kg/Hr

Cpof TEG = 1.997103 kJ/g C

Cp= 1.997103 kJ/Kg-K

Rich solvent temperature =30C

T1= 200C = 473.15 K

T2= 329.15 K

Q = m Cp(T2- T1)

Q = (58,571 Kg/Hr) (1.997103 kJ/g C) (473.15 K - 329.15 K)

Q = 168,444,014 kJ/hr

Q = 168,444,014 kJ/hr (1 hr/3600 s)

Q = 4,678.89 kW

b. Recovery Column

Cpof aromatics = 1.7867 kJ/Kg-K

T1= 38C = 311.15 K

T2 = 56C = 329.15 K

Q1= m Cp(T2- T1)

Q1= (50875.47 Kg/Hr) (1.7867 kJ/Kg-K) (450.15 K - 408.15 K)

Q1 = 1,636,185.64 kJ/hr

Q1= 1,636,185.64 kJ/hr (1 hr/3600 s)

Q1= 454.50 kW


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c. Benzene Column

M = 13,987.2645 Kg/Hr

Cpof Benzene = 1.968 kJ/Kg-K

T1= 425C = 698.15 K

T2= 100C = 373.15 K

Q = m Cp(T2- T1)

Q = (13,987.2645 Kg/Hr) (1.968kJ/Kg-K) (698.15 K - 373.15 K)

Q = 8,946,254.374 kJ/hr

Q = 8,946,254.374 kJ/hr (1 hr/3600 s)

Q = 2,485.07066 kW

d. Toluene Column

M = 9,433.5147.28 Kg/Hr

Cpof Toluene = 1.72 kJ/Kg-K

T1= 100C = 373.15 K

T2= 125C = 398.15 K

Q = m Cp(T2- T1)

Q = (9,433.5147 Kg/Hr) (1.72 kJ/Kg-K) (398.15 K - 373.15 K)

Q = 405,641 kJ/hr

Q = 405,641 kJ/hr (1 hr/3600 s)

Q = 112.68 kW


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e. Xylene Column

M = 2.096.9148 Kg/Hr

Cpof Xylene = 1.72 kJ/Kg-K

T1= 125C = 398.15 K

T2= 160C = 433.15 K

Q = m Cp(T2- T1)

Q = (2.096.9148 Kg/Hr) (1.72 kJ/Kg-K) (433.15 K - 398.15 K)

Q = 126,224.21 kJ/hr

Q = 126,224.21 kJ/hr (1 hr/3600 s)

Q = 35.07 kW

f. Boiler

Q = (4, 678.89 + 454.50 + 2,424.4592 + 112.68 + 35.07) kW

Q = 3,342.2692 kW

Cpof steam = 1.996 kJ/Kg-K

T1= 100C = 373.15 K

T2 = 350C = 623.15 K

Q = m Cp(T2- T1)

342.2692 kW (1 kJ/s / 1 kW) (3600s/1 hr) = (M s) (1.996 kJ/Kg-K) (623.15 K -

373.15 K)

Ms= 2,469.2769 kg/hr


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Table 2. Summary of Energy Requirements for Heating

Process Energy requirement (kW)

Stripping 4, 678.89

Solvent Recovery 454.50Benzene Distillation 2,424.4592

Toluene Distillation 35.07

Xylene Distillation 112.68

Total energy requirement 7,705.5992 kW

2. COOLING EQUIPMENT

a. Stripper Column

Mass of incoming aromatics:23,267 Kg/Hr


Temperature of incoming aromatics:200OC

Temperature of leaving aromatics:56 OC

Mass of incoming solvent:45, 118.58 Kg/Hr


Temperature of incoming solvent:200 OC

Temperature of leaving solvent:56 OC

Specific heat of seawater:3.985 kj/kgoC

Temperature of incoming cooling water:17 OC

Temperature of leaving cooling water:30 OC


(23,267 Kg/Hr)(1.825 kJ/kgOC)(200OC-56 OC) + (45, 118.58 Kg/Hr)(1.997103

kJ/g C)(200OC-56 OC) = m (3.985 kJ/kgOC)(30 OC-17 OC)


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mCW= 368, 495.2536 Kg/hr

QA = 1,698.491 KJ/s

QS = 3,604.258 KJ/s s

b. Recovery Column

Mass of incoming aromatics:69,771 Kg/Hr


Temperature of incoming aromatics: 56OC

Temperature of leaving aromatics:38

O

C

Mass of incoming solvent:58,571Kg/Hr


Temperature of incoming solvent:56 OC

Temperature of leaving solvent:38 OC

Specific heat of seawater:3.985 kj/kgoc

Temperature of incoming cooling water:17 OC

Temperature of leaving cooling water:30 OC


(69,771 Kg/Hr)(1.825 kJ/kgOC)(56OC-38OC) + (58,571Kg/Hr)(1.997103 kJ/g

C)(56OC-38OC) = m (3.985 kJ/kgOC)(30 OC-17 OC)

mCW= 258, 783.1112 Kg/hr

QA = 636.1129 KJ/s

QS = 584. 862 KJ/s


44/204

d. Benzene Column

Mass of incoming benzene:2,096.9148 Kg/Hr

Incoming benzene temperature:100c

Leaving benzene temperature:25c

Specific heat of benzene:1.968 kj/kgok

Incoming cooling water temperature:30OC

Leaving cooling water temperature:17 OC

Specific heat of sea water:3.985 kj/kgoc

[mCp(T2-T1)]BW= [mCp(T2-T1)]CW

(2,096.9148 Kg/Hr)(1.968 kJ/kgOC)(100OC-25 OC) = m(3.985 kJ/kgOC)(30OC-17

OC)

mCW= 5,974.4160 Kg/hr

QB = 85.97 KJ/s

QCW = 85.97 KJ/s s

e. Toluene Column

Mass of incoming toluene:2,096.9148 Kg/Hr

Incoming toluene temperature:125c

Leaving toluene temperature:25c

Specific heat of toluene:1.72 kj/kgoc





45/204

[mCp(T2-T1)]T= [mCp(T2-T1)]CW

(9,433.5147Kg/Hr)(1.72 kJ/kgOC)(125 C-25 C) = m(3.985 kJ/kgOC)(30OC-17 OC)

mCW= 31,320.614 Kg/hr

QT = 450.712 KJ/s

QCW = 450.712 KJ/s

f. Xylene Column

Mass of incoming xylene: 1,477.7265 Kg/Hr

Incoming xylene temperature:160c

Leaving xylene temperature:25c

Specific heat of xylene:1.72 kj/kgoc




[mCp(T2-T1)]X= [mCp(T2-T1)]CW

(1,477.7265 Kg/Hr)(1.72 kJ/kgOC )(160C-25 C) = m(3.985 kJ/kgOC)(30OC-17 OC)

mCW= 6,738.980516 Kg/hr

Qx = 95.31 KJ/s

QCW = 95.31 KJ/s

g. C9+ Tank

mass of incoming C9+ aromatics:979.1085 Kg/Hr

incoming C9+ aromatics temperature:160C


46/204

leaving C9+ aromatics temperature:25C

specific heat of C9+ aromatics:1.72 kJ/kgOC

incoming cooling water temperature:30OC

leaving cooling water temperature:17 OC

specific heat of sea water:3.985 kJ/kgOC


(979.1085 Kg/Hr)(1.72 kJ/kgOC )(160C-25 C) = m(3.985 kJ/kgOC)(30OC-17 OC)

mCW= 4,985.553107 Kg/hr

QC9+ = 64.254 KJ/s

QCW = 64.254 KJ/s

Table 3. Summary of Energy Requirement for Cooling

Process Energy requirement (kW)

Stripping 1,698.491 kW

Solvent Recovery 636.1129 kWBenzene Distillation 85.97 kW

Toluene Distillation 450.712 kW

Xylene Distillation 95.31 kW

C9+ Aromatics 64.254 kW

Total energy requirement 3,021.8499 kW

F. Capacity Calculation

Feed Surge Tank

Feed = 17,000 kg/hr

= 759 kg/m3


47/204

Minimum Level = 50%

V = [17,000 kg/hr (1 m3 / 759 kg)] (1.5)

V= 33.5968 m3/ hr (24 hr / day)

V = 806.3241 m3/ day

a. Benzene Product Tank

Benzene Product = 2,049.4214 kg/hr

= 876 kg/m

Minimum Level = 50%

V = 2,049.4214 kg/hr (1 m/876 kg) (1.5)

V = (3.509 m3/ hr) (24 hr / day)

V = 84.22 m3/day

b. Toluene Product Tank

Toluene Product = 9,219.85 kg/hr

= 876 kg/m

Minimum Level = 50%

V = 9,219.85 kg/hr (1 m/876 kg) (1.5)

V = (15.7874 m3/ hr) (24 hr / day)

V = 378.89 m3/day

c. Xylene Product Tank

Toluene Product = 1, 444.2572 kg/hr


48/204

= 870 kg/m

Minimum Level = 50%

V = 1, 444.2572 kg/hr (1 m/870 kg) (1.5)

V = (2.49 m3/ hr) (24 hr / day)

V = 59.76

d. C9+Aromatics Tank

C9+By-Product = 956.9359 kg/hr

= 914.4 kg/m

V = 956.9359 kg/hr (1 m3/ 914.4 kg)

V = 1.05 m3/hr (24 hr / day)

V = 25.12 m3/day

G. Plant Efficiency

The plant efficiency can be calculated from the mass balance data:

Efficiency = (output)/ (input) x 100%

Efficiency = (BTX)/Naphtha Reformate x 100%

Efficiency = (12,713.5286 kg/hr) / (17000 kg/hr) x 100%

Efficiency = 74.79 %


49/204

2. Design Option II

A. Process Description

Figure 8. Design option II Process flow diagram

Naphtha reformate will pass through the distillation column to separate non-

aromatic component to aromatic component with the use of NFM solvent at 150

degree Celsius and 15 psig. After this, non-aromatic will go directly to the storage

tank while aromatic component along with the extracting solvent will go to the

stripping column for the separation of aromatics component to the solvent used

during extraction process. Stripping column is at 56 degree Celsius and 15psig.

After this process, aromatics fraction will go to the fractionation column for the

fractionation of Benzene, Toluene and Xylene at the desired pressure and

temperature.


50/204

B. Plant Lay-out

Figure 10. Plant Top view


Legend:

1Area for Expansion

2Process Area

3Fire Fighting Unit

4Control Room


6Laboratory

7Plant Utilities



10Workshop

11Change RoomArea for Expansion


13Canteen

14Administration Building

15 - Area for Expansion

16Security



51/204

C. Equipment Specification

Specification Sheet No. 1VESSEL A

Shell Material A515 (Carbon Steel Plates for pressure

vessels for intermediate and highertemperature service)

Design Temperature can withstand 150C

Design Pressure 15psig

Diameter 8 feet

Length 14 feet

Orientation vertical

Specification Sheet No. 2VESSEL B


vessels for intermediate and higher

temperature service)

Design Temperature can withstand 150C

Design Pressure 15psig

Diameter 10 feet

Length 17.5 feet

Orientation vertical

Specification Sheet No. 3PUMP B

Type Inline pump


Maximum Temperature 175

Maximum capacity 300 gpm



PUMP C

Type Inline pump


Maximum Temperature 175

Maximum capacity 60 GPM



52/204


PUMP D

Type Inline pump


Maximum Temperature 175Maximum capacity 20 gpm



PUMP E

Type Inline pump


Maximum Temperature 175Maximum capacity 100 gpm



HEAT EXCHANGER A

Type shell and tube heat exchanger

Shell Material A285C (Low and intermediate strength

carbon steel plates for pressure vessels.)Inside Diameter 6ft

Outside Diameter 6.60ft

Maximum Shell Temperature 350C

Maximum Shell Pressure 150 psig

Incoming pipe Diameter 0.75in, scheduled 40

Outlet Pipe diameter 1.25in, scheduled 40

Tube Material A214 (Electric-resistance-welded carbon

steel heat exchanger and condenser tubes)

Maximum Tube Temperature 350C

Maximum Tube Pressure 150 psig

Tube Length 15 feet (average)


Outlet pipe Diameter 1.25in, scheduled 40

Number of passes 2, U-bend configuration

Area 1000 ft2


53/204

.Specification Sheet No. 8

HEAT EXCHANGER B



carbon steel plates for pressurevessels.)

Inside Diameter 6ft






Tube Material A214 (Electric-resistance-welded

carbon steel heat exchanger and

condenser tubes)






Number of tubes 28


Area 900 ft2


54/204


HEAT EXCHANGER C



carbon steel plates for pressurevessels.)

Inside Diameter 6ft







carbon steel heat exchanger andcondenser tubes)






Number of tubes 28


Area 500 ft2


Boiler

Type Fire-tube boiler


carbon steel heat exchanger and

condenser tubes)Design Pressure 500 psig

Design Temperature 400C

Heat Duty 25 million BTU per hour


55/204

Specification Sheet No. 11DISTILLATION COLUMN

Shell Material A515 (Carbon Steel Plates for pressure vessels for

intermediate and higher temperature service)

Number of tray 60

Column temperature 150

Pressure 15psig

Height 32m

Diameter 1.5m

Tray Material A285C (Low and intermediate strength carbon steel

plates for pressure vessels.)

Feed tray 30thfrom the bottom

Type of tray bubble cap tray

Tray spacing 18in

Hole diameter 5mmHole spacing 15mm (triangular)

Tray thickness 3mm

Weir height 45 mm

Specification Sheet No. 12STRIPPING COLUMN



temperature service)Number of tray 30

Column temperature 56

Pressure 5psig

Height 14m

Diameter 1.25m

Tray Material A285C (Low and intermediate strength

carbon steel plates for pressure

vessels.)

Feed tray 5thfrom the bottom

Type of tray bubble cap tray

Tray spacing 15.75in

Hole diameter 5mm

Hole spacing 15mm (triangular)

Tray thickness 3mm

Weir height 45 mm


56/204

D. Material Balance

Assumptions:






distillation.

Table 5. Aromatics Composition of Reformate

Benzene 11.98 %

Toluene 53.88 %

Xylene 8.44 %

C9 aromatics 5.00 %

Paraffin 20.7 %

Feed = 17,150 kg/hr



N-Formyl Morpholine = 42,875 kg/hr


reference amount for Sulfolane used for aromatics extraction solvent.


57/204

Figure 13. Extractive Distillation Section

f. Pump 1

M1= M2

M1= 17,150 kg/hr - - - - - - - - - - mass of reformate

M2= 17,150 kg/hr - - - - - - - - - - mass of reformate

g. Cooling System 1 (condenser 1)

M3 = M4

M3= 42,875 kg/hr - - - - - - - - - - mass of solvent

M4= - - - - - - - - - - mass of solvent

h. Extractive Distillation Column

recovery = 96% of non-aromatic content

M2+ M4 = M5+ M6

17,150 + 42,875 = M5 + 0.04*0.207*17,150 + 0.793*17,150* + 42,875


58/204

M5= 3,408.05 kg/hr - - - - - - - - - - mass of raffinate (mostly paraffin)

M6= 56,616.95 kg/hr - - - - - - - - - - mass of rich solvent

i. Cooling System 2 (condenser2 and pump 2)

non-aromatic reflux = 1.5%

M5= M7+ M8

3,408.05 = 3,408.05*.015 + M8

M5= 3,408.05 kg/hr - - - - - - - - - - mass of non-aromatics

M7= 51.13 kg/hr - - - - - - - - - - mass of non-aromatics reflux

M8 =3,356.93 kg/hr - - - - - - - - - - mass of non-aromatics product

j. Pump 3

M6= M9

M6= 56,615.95 kg/hr - - - - - - - - - - mass of aromatics

M9=56,615.95 kg/hr - - - - - - - - - - mass of aromatics

k. Stripper Column

recovery = 99.85% of solvent

rich solvent = aromatics + solvent recovered

M6= M10+ M11

56,616.95 = M10+ 42,875*0.9985


M11= 42,810.69 kg/hr - - - - - - - - - - mass of mass of stripped solvent


59/204

l. Cooling System 3 (condenser 3, pump 4)

aromatic reflux = 1.5%

M10= M12+ M13

13,806.26 = 13806.26*.015 + M13


M12= 207.09 kg/hr - - - - - - - - - - mass of aromatics reflux

M13= 13,599.17 kg/hr - - - - - - - - - - mass of aromatics output

Figure 14. Fractionation Section

m. Benzene Fractionation Column

recovery = 94.5% of benzene component

M13= M14+ M15

13,599.17 = 17,150*0.1,198*0.945 + M15

M13= 13,599.17 kg/hr - - - - - - - - - - mass of input aromatics


60/204

M14= 1,941.57 kg/hr - - - - - - - - - - mass of benzene output

M15= 11,657.60 kg/hr - - - - - - - - - mass of mixed toluene, xylene & C9

n. Cooling System 4 (condenser4, pump5)

benzene reflux = 1.5%

M14= M16+ M17

1,941.57 = 1,941.57*0.015 + M17

M14= 1,941.57 kg/hr - - - - - - - - - - mass of benzene output

M16= 29.12 kg/hr - - - - - - - - - - mass of benzene reflux

M17= 1,912.45 kg/hr - - - - - - - - - - mass of benzene product

o. Pump 6

M15= M18

M15= 11,657.60 kg/hr - - - - - - - - - - mass of mixed toluene, xylene &C9


p. Toluene Fractionation Column

recovery = 97% of toluene

M18= M19+ M20

11,657.60 = 17,150*0.5388*0.97 + M20


M19= 8,963.21 kg/hr - - - - - - - - - - mass of toluene output

M20= 2,694.39 kg/hr - - - - - - - - - mass of mixed xylene & C9 aromatics


61/204

q. Cooling System 5 (condenser5, pump7)

toluene reflux = 1.5%

M19= M21+ M22

8,963.21 = 8,963.21*0.015 + M22

M19= 8,963.21 kg/hr - - - - - - - - - - mass of toluene output

M21= 134.44815 kg/hr - - - - - - - - - - mass of toluene reflux

M22= 8,828.76 kg/hr - - - - - - - - - - mass of toluene product

r. Pump 8

M20= M23

M20= 2,694.39 kg/hr - - - - - - - - - mass of mixed xylene &C9 aromatics


s. Xylene Fractionation Column

Recovery = 97% of xylene

M23= M24+ M25

2,694.39 = 17,150*0.0844*0.97 + M25


M24= 1,404.04 kg/hr - - - - - - - - - - mass of xylene output

M25= 1,290.35 kg/hr - - - - - - - - - - mass of C9 aromatics


62/204

t. Cooling System 6 (condenser7, pump9)

xylene reflux = 1.5%

M24= M26+ M27

1,404.04 = 1,404.04*0.015 + M27

M24= 1,404.04 kg/hr - - - - - - - - - - mass of xylene output

M26= 21.06 kg/hr - - - - - - - - - - mass of xylene reflux

M27= 1,382.98 kg/hr - - - - - - - - - - mass of xylene product

Table 6. Summary of in-flow rates and out-flow rates

Equipment In-Flow Rate (kg/hr) Out-Flow Rate (kg/hr)Pump 1 17,150Cooling System 1(condenser 1)

42,875

Extractive Distillation Column 60,024.95Cooling System 2(condenser2 and pump 2)

3,408.05 3,356.93

Pump 3 56,615.95Stripper Column 13,806.26 42,810.69Cooling System 3(condenser 3, pump 4)

13,806.26 13,599.17

Benzene FractionationColumn

13,599.17 1,941.57

Cooling System 4(condenser4, pump5)

1,941.57 1,912.45

Pump 6 11,657.60Toluene FractionationColumn

11,657.60 8,963.21


8,963.21 8,828.76

Pump 8 2,694.39Xylene Fractionation Column 2,694.39 1,404.04


1,404.04 1,382.98

Benzene Product 1,941.57Toluene Product 8,963.21

Mixed Xylene Product 1,404.04BTX Product 12,308.82 kg/hr


63/204

Production per hour = 12,308.82 kg/hr

Production per year = (12,308.82 kg/hr) (24 hrs/day) (355 stream days/year)

Production per year = 104,871,146.40 kg/year

E. Energy balance

This section contains the calculations for energy requirements of heat

transfer equipment used in the BTX Manufacturing Plant.

HEATING EQUIPMENT

a. Extractive Distillation Column

temperature of column:150 OC

temperature of incoming reformate: 50OC

temperature of incoming solvent: 50 OC

specific heat of reformate: 1.7867 kJ/kgOC

specific heat of solvent: 4.184 kJ/kgOC

mass of reformate: 17,150 kg/hr

mass of solvent: 42,875 kg/hr

specific heat of steam: 1.996 kJ/kgOC

temperature of incoming steam: 300 OC

temperature of leaving steam: 100 OC

heat gain of reformate and solvent is equal to heat lost by steam

[mCp(T2-T1)]REFORMATE+ [mCp(T2-T1)]SOLVENT= [mCp(T2-T1)]STEAM

17,150*1.7867*(150-50) + 42,875*4.184*(150-50) = m*1.996*(300-100)


64/204

m = 52,612.95 kg/hr - - - - - - - - - - mass of steam required

QREFORMATE= 851.16 kJ/s - - - - - - - - - - heat gained by reformate

QSOLVENT= 4,983.03 kJ/s - - - - - - - - - - heat gained by solvent

QSTEAM= 5,834.19 kJ/s - - - - - - - - - - heat loss of steam

b. Benzene Fractionation Column

temperature of column: 95 OC

temperature of incoming aromatics: 56 OC

specific heat of benzene: 1.856 kJ/kg

O

C

specific heat of mixed toluene, xylene and C9aromatics: 1.825 kJ/kgOC




mass of benzene: 2,054.57 kg/hr

mass of mixed toluene, xylene and C9aromatics: 11,687.38 kg/hr

heat gain of benzene and mixture is equal to heat lost by steam

[mCp(T2-T1)]BENZENE+ [mCp(T2-T1)]MIXTURE= [mCp(T2-T1)]STEAM

2,054.57*1.856*(95-56) + 11,687.38*1.825*(95-56) = m*1.996*(300-100)

m = 2,456.33 kg/hr - - - - - - - - - - mass of steam required

QBENZENE= 148,717.99 kJ/s - - - - - - - - - - heat gained by benzene

QMIXTURE= 831,849.27 kJ/s - - - - - - - - - - heat gained by mixture

QSTEAM= 272.38 kJ/s kJ/s - - - - - - - - - - heat loss of steam


65/204

c. Toluene Fractionation Column


temperature of mixed xylene and C9aromatics: 95 OC

specific heat of toluene: 1.809 kJ/kgOC

specific heat of mixed xylene and C9aromatics: 1.825 kJ/kgOC



temperature of leaving steam: 100

O

C

mass of toluene: 9,240.42 kg/hr

mass of mixed xylene and C9aromatics: 2,559.96 kg/hr

heat gain of toluene and mixture is equal to heat lost by steam

[mCp(T2-T1)]TOLUENE+ [mCp(T2-T1)]MIXTURE= [mCp(T2-T1)]STEAM

9,240.42*1.809*(125-95) + 2,559.96*1.825*(125-95) = m*1.996*(300-100)

m = 1607.30 kg/hr - - - - - - - - - - mass of steam required

QTOLUENE= 501,477.59 kJ/s - - - - - - - - - - heat gained by toluene

QMIXTURE= 140,157.81 kJ/s - - - - - - - - - - heat gained by mixture

QSTEAM= 178.23 kJ/s kJ/s - - - - - - - - - - heat loss of steam

d. Xylene Fractionation Column


temperature of C9aromatics: 125 OC


66/204

specific heat of xylene: 1.841 kJ/kgOC

specific heat of C9aromatics: 1.841 kJ/kgOC




mass of xylene: 1,447.46 kg/hr

mass of C9aromatics: 1,389.71 kg/hr

heat gain of xylene and C9aromatics is equal to heat lost by steam

[mCp(T2-T1)]XYLENE+ [mCp(T2-T1)]C9 AROMATICS= [mCp(T2-T1)]STEAM

1,447.46*1.841*(155-125) + 1,389.71*1.841*(155-125) = m*1.996*(300-100)

m = 392.53 kg/hr - - - - - - - - - - mass of steam required

QXYLENE= 79,943.22 kJ/s - - - - - - - - - - heat gained by xylene

QC9 AROMATICS= 76,753.68 kJ/s - - - - - - - - - - heat gained by C9 aromatics

QSTEAM= 43.53 kJ/s - - - - - - - - - - heat loss of steam

Table 7. Summary of Energy Requirement for Heating

Process Energy requirement (kW) mass of steamrequirement

Extractive DistillationColumn

851.16 52,612.95

Benzene FractionationColumn 148,717.99 2,456.33

Toluene FractionationColumn

501,477.59 1,607.30

Xylene FractionationColumn

79,943.22 392.53

Total energy requirement 724389.96 kW 57,069.11


67/204

COOLING EQUIPMENT

a. Non-aromatics Cooler

mass of incoming non-aromatics: 3,408.05 kg/hr

incoming non-aromatics temperature: 150 OC

leaving non-aromatics temperature: 30 OC

specific heat of non-aromatics: 1.7867 kJ/kgOC

incoming cooling water temperature: 17 OC

leaving cooling water temperature: 30 OC

specific heat of sea water: 3.985 kJ/kg

O

C

heat lost by non-aromatics is equal to heat gained by cooling water

[mCp(T2-T1)]NA= [mCp(T2-T1)]CW

3,408.05*1.7867*(150-30) = m*3.985*(30-17)

m = 14,104.81 kg/hr - - - - - - - - - - required mass of cooling water

QNA= 202.97 kJ/s - - - - - - - - - - heat loss by non-aromatics

QCW= 202.97 kJ/s - - - - - - - - - - heat gained by cooling water

b. Aromatics Cooler

mass of incoming non aromatics: 13,806.26 kg/hr

incoming aromatics temperature: 56 OC

leaving aromatics temperature: 30 OC

specific heat of aromatics: 1.825 kJ/kgOC



68/204


specific heat of seawater: 3.985 kJ/kgOC

heat lost by aromatics is equal to heat gained by cooling water

[mCp(T2-T1)]A= [mCp(T2-T1)]CW

13,806.26*1.825*(56-30) = m*3.985*(30-17)

m = 12,645.63 - - - - - - - - - - required mass of cooling water

QA= 181.97 kJ/s - - - - - - - - - - heat loss by aromatics


c. Stripper Column

mass of incoming aromatics: 13741.95 kg/hr

specific heat of aromatics: 1.825 kJ/kgOC

temperature of incoming aromatics:150 OC

temperature of leaving aromatics: 56 OC

mass of incoming solvent: 42,875 kg/hr

specific heat of solvent: 4.184 kJ/kgOC

temperature of incoming solvent: 150 OC

temperature of leaving solvent: 56 OC

specific heat of seawater: 3.985 kJ/kgOC

temperature of incoming cooling water: 17 OC

temperature of leaving cooling water: 30 OC


69/204

heat lost by aromatics and solvent is equal to heat gained by cooling water


13,741.95*1.825*(150-56) + 42,875*4.184*(150-56) = m*3.985*(30-17)


QA= 654.84 kJ/s - - - - - - - - - - heat loss by aromatics

QA= 4,684.09 kJ/s - - - - - - - - - - heat loss by solvent

QCW= 5,338.89 kJ/s - - - - - - - - - - heat gained by cooling water

d. Benzene Cooler

mass of incoming benzene: 1,941.57 kg/hr

incoming benzene temperature: 95 OC

leaving benzene temperature: 30 OC

specific heat of benzene: 1.856 kJ/kgOC



specific heat of sea water: 3.985 kJ/kgOC

heat lost by benzene is equal to heat gained by cooling water

[mCp(T2-T1)]B= [mCp(T2-T1)]CW

1941.57*1.856*(95-30) = m*3.985*(30-17)


QB= 65.06 - - - - - - - - - - heat loss by benzene



70/204

e. Toluene Cooler

mass of incoming toluene: 8,963.21 kg/hr

incoming toluene temperature: 125 OC

leaving toluene temperature: 30 OC

specific heat of toluene: 1.809 kJ/kgOC




heat lost by toluene is equal to heat gained by cooling water


8,963.21*1.809*(125-30) = m*3.985*(30-17)


QT= 427.88 - - - - - - - - - - heat loss by toluene


f. Xylene Cooler

mass of incoming xylene: 1,404.04 kg/hr

incoming xylene temperature: 155 OC

leaving xylene temperature: 30 OC

specific heat of xylene: 1.841 kJ/kgOC




71/204


heat lost by xylene is equal to heat gained by cooling water

[mCp(T2-T1)]X= [mCp(T2-T1)]CW

1,404.04*1.841*(155-30) = m*3.985*(30-17)


QX= 89.75 - - - - - - - - - - heat loss by xylene


g. C9Aromatics

mass of incoming C9+ aromatics: 1,290.35 kg/hr

incoming C9+ aromatics temperature: 155C

leaving C9+ aromatics temperature: 30C

specific heat of C9+ aromatics: 1.72 kJ/kgOC

incoming cooling water temperature: 30OC




1,290.35*1.72*(155C-30 C) = m3.985*(30OC-17 OC)

mCW= 5,355.183 Kg/hr

QC9+ = 77.0625 KJ/s

QCW = 77.0625 KJ/s


72/204

Table 8. Summary of Energy Requirement for Cooling

Process Energy requirement (kW) Mass of cooling

water requirement

Non-aromatics Cooler 202.97 kW 14104.81

Aromatics Cooler 181.97 kW 12645.63Stripper Column 654.84 kW 371006.61

Benzene Cooler 65.06 kW 4521.40

Toluene Cooler 427.88 kW 29734.05

Xylene Cooler 89.75 kW 6236.94

C9+ Tank 77.0625 kW 14104.81

Total energy requirement 1,609.6525 kW 451754.25

A. Capacity Calculation

a. Feed Surge Tank

Feed = 17,150 kg/hr

= 759 kg/m3

Minimum Level = 50%

V = feed rate * time * (1m3/759kg)

= 17,150 * 2 * (1m3/759kg)

V = 45 m3

b. Non-aromatic Vessel

Feed = 3408.05 kg/hr

= 845 kg/m3

Minimum Level = 50%


= 3408.05 * 2 * (1m3/845kg)

V = 8.07 m3


73/204

c. Aromatic Vessel

Feed = 13,806.26 kg/hr

= 874 kg/m3

Minimum Level = 50%

V = feed rate * time * (1m3/874 kg)

= 13,806.26 * 2 * (1m3/874 kg)

V = 31.59 m3

d. Benzene Vessel

Feed = 1,941.75 kg/hr

= 876.5 kg/m3

Minimum Level = 50%

V = feed rate * time * (1m3/876.5 kg)

= 1,941.75 * 2 * (1m3/876.5 kg)

V = 4.43 m3

e. Toluene Vessel

Feed = 8,963.21 kg/hr

= 866.9 kg/m3

Minimum Level = 50%


= 8,963.21 * 2 * (1m3/866.9 kg)

V = 21.67 m3


74/204

f. Xylene Vessel

Feed = 1,404.04 kg/hr

= 864 kg/m3

Minimum Level = 50%


= 1,404.04 * 2 * (1m3/864kg)

V = 3.25 m3

g. C9+

Aromatics Vessel

Feed = 1,290.35 kg/hr

= 876.5 kg/m3

Minimum Level = 50%


= 1,290.35 * 2 * (1m3/876.5 kg)

V = 3.0 m3

Efficiency =

100%

.+.+.

100%

= 70.69%

Production per hour = 11, 964.21 kg/hr

Production per year = (11,964.21 kg/hr) (24 hrs/day) (360 stream days/year)

Production per year = 103, 370 ,774.4 kg/year


75/204

3. Design Option III

A. Process Description

Figure 15. Design Option III Process Flow Diagram

Fresh feed enters the extractor and flows upward, countercurrent to a

stream of lean solvent. As the feed flows through the extractor, aromatics are

selectively dissolved in the solvent. A raffinate stream, very low in aromatics

content, is withdrawn from the top of the extractor. The rich solvent, loaded with

aromatics, exits the bottom of the extractor and enters the stripper. The

nonaromatic components having volatilities higher than that of benzene are

completely separated from the solvent by extractive distillation and removed


76/204

overhead along with a small quantity of aromatics. This overhead stream is

recycled to the extractor, where the light non-aromatics displace the heavy non-

aromatics from the solvent phase leaving the bottom of the extractor.

The stripper bottoms stream, which is substantially free of nonaromatic

impurities, is sent to the recovery column, where the aromatic product is separated

from the solvent. Because of the large difference in boiling point between the

Sulfolane solvent and the heaviest aromatic component, this separation is

accomplished with minimal energy input. To minimize solvent temperatures, the

recovery column is operated under vacuum. Lean solvent from the bottom of the

recovery column is returned to the extractor. The extract is recovered overhead

and sent on to distillation columns downstream for recovery of the individual

benzene and toluene products. The raffinate stream exits the top of the extractor

and is directed to the raffinate wash column. In the wash column, the raffinate is

contacted with water to remove dissolved solvent. The solvent-rich water is

vaporized in the water stripper by exchange with hot circulating solvent and then

used as stripping steam in the recovery column. Accumulated solvent from the

bottom of the water stripper is pumped back to the recovery column.

The raffinate product exits the top of the raffinate wash column. The amount

of Sulfolane solvent retained in the raffinate is negligible. The raffinate product is

commonly used for gasoline blending or aliphatic solvent applications. Under

normal operating conditions, Sulfolane solvent undergoes only minor oxidative

degradation. A small solvent regenerator is included in the design of the unit as a

safeguard against the possibility of air leaking into the unit. During normal


77/204

operation, a small slip-stream of circulating solvent is directed to the solvent

regenerator for removal of oxidized solvent. The extract product from a Sulfolane

unit may contain trace amounts of olefins and other impurities that would adversely

affect the acid-wash color tests of the final benzene and toluene products. To

eliminate these trace impurities, the extract is clay-treated prior to fractionation.

Because clay treating is done at mild conditions, clay consumption is minimal. The

treated extract is directed to the aromatics fractionation section, where high-purity

benzene, toluene, and mixed xylenes are recovered.

Any heavy aromatics in the feed are yielded as a bottoms product from the

fractionation section. In most cases, the C9 aromatics are recovered. The heavy

aromatics may also be blended back into the refinery gasoline pool or sold as a

high-octane blending component.


78/204

B. Plant Lay-out

Figure 16. Plant Top View


Legend:

1Process Area2Fire Fighting Unit

3Control Room


5Laboratory

6Plant Utilities




10Workshop

11Change Room

Area for Expansion

12Canteen

13Administration Building


15Gate 1

16Security

17Gate 2

18Area for Expansion


79/204

C. Equipment Specification


PUMP 1

Flow 120 gpm

Type Centrifugal


Temperature 100C





EXTRACTOR 1

Height 17 meters

Diameter 0.93 meters

Pressure 120 psi

Temperature 200C




80/204


COOLER 1

Type Liquid-Liquid

Process DistillationDuty 100 kW

Temperature 150 C

Pressure 30 psi


steel plates

Area 1000ft2


Length 1.95m

Inside Diameter 0.1625mIncoming pipe diameter in, schedule 40 stainless steel


Tubes Number of Tubes 28



Length 1.905m









81/204


WASH COLUMN

Height 6.09 meters

Diameter 0.44 metersPressure 30 psi

Temperature 100C

Tray type Sieve

Number of Trays 18

Tray Spacing 0.02 m

Tray thickness 0.005 m


steel plates


Specification Sheet No. 5STRIPPING COLUMN

Height 14 meters


Pressure 30 psi

Temperature 150 C

Tray type Sieve

Number of Trays 34Tray Spacing 0.6096 m



steel plates


Specification Sheet No. 6PUMP 2

Flow 120 gpm

Type Centrifugal

Discharge Pressure 45 psi

Temperature 150 C





82/204


COOLER 2

Type Liquid-Liquid


Temperature 200 C

Pressure 45 psi


steel plates

Area 1000ft2


Length 1.95m






Length 1.905m









83/204


SEPARATOR

Type Gas-Liquid

Length 4.80 metersDiameter 1 meter

Oreintation Horizontal

Pressure 30 psi

Temperature 150 C

Material of Construction Carbon Steel Plates


Specification Sheet No. 9WATER SEPARATOR

Type Liquid-Liquid

Length 4.80 meters

Diameter 1 meter


Pressure 30 psi

Temperature 150 C



Specification Sheet No. 10REGENERATOR

Height 10 meters

Diameter 1.2 meters

Pressure 45 psi

Temperature 200 C

Tray type Sieve

Number of Trays 30

Tray Spacing 0.04 m



steel plates



84/204


Flow 120 gpm

Type Centrifugal


Temperature 200 C




Specification Sheet No. 12RECOVERY COLUMN

Height 14 meters

Diameter 3 meters

Pressure 55 psi

Temperature 200 C

Tray type Sieve

Number of Trays 33

Tray Spacing 0.40 m



steel platesMaterials of Constructions Stainless Steel


PUMP 4

Flow 120 gpm

Type Centrifugal

Discharge Pressure 65 psiTemperature 200 C





85/204


COOLER 3

Type Liquid-Liquid


Temperature 200 C

Pressure 45 psi


steel plates

Area 1000ft2


Length 1.95m






Length 1.905m









86/204

Specification Sheet No. 15SEPARATOR 2

Type Liquid-Liquid

Length 4.80 meters

Diameter 1 meter


Pressure 45 psi

Temperature 200 C




Flow 120 gpm

Type Centrifugal


Temperature 200 C





Flow 120 gpm

Type Centrifugal


Temperature 200 C





87/204

Specification Sheet No. 18CLAY TREATER

Cartridge 1 Cartridge 2

Height 7.6 m 7.6 m

Diameter 0.93m 1.2 m

Pressure 30 psi 65 psi

Temperature 100C 425C

Materials of

Constructions

Welded Carbon

steels

Welded Carbon steels


BENZENE COLUMN

Height 17 meters


Pressure 15 psi

Temperature 100 C



Materials of Constructions Carbon Steel


PUMP 7

Flow 120 gpm

Type Centrifugal


Temperature 100 C





88/204


COOLER 4

Type Liquid-Liquid


Temperature 150 C

Pressure 30 psi


steel plates

Area 1000ft2


Length 1.95m






Length 1.905m









89/204


TOLUENE COLUMN

Height 20 metersDiameter 1.04 meters

Pressure 15 psi

Temperature 125 C





PUMP 8

Flow 120 gpm

Type Centrifugal


Temperature 180 C





XYLENE COLUMN

Height 18 meters


Pressure 15 psi

Temperature 180C





90/204


COOLER 5

Type Liquid-Liquid


Duty 100 kWTemperature 125 C

Pressure 30 psi


steel plates

Area 1000ft2


Length 1.95m


Incoming pipe diameter in, schedule 40 stainless steelOutlet pipe diameter 1 in, schedule 40 stainless steel




Length 1.905m









91/204

Specification Sheet No. 26COOLER 6

Type Liquid-LiquidProcess Distillation

Duty 100 kW

Temperature 180 C

Pressure 30 psi


steel plates

Area 1000ft2


Length 1.95mInside Diameter 0.1625m






Length 1.905m









92/204


PUMP 8

Flow 120 gpm

Type Centrifugal


Temperature 180 C





VESSEL AHeight 3.05 m

Diameter 1.22 m

Oreintation Vertical

Pressure 45 psi

Temperature 150 C

Material of Construction A515 (Carbon Steel Plates for pressure


temperature service)


Specification Sheet No. 29VESSEL B

Height 5.2 m

Diameter 2.3 m

Oreintation Vertical

Pressure 45 psi

Temperature 150 C

Material of Construction A515 (Carbon Steel Plates for pressure

vessels for intermediate and highertemperature service)



93/204


COOLER 7

Type Liquid-Liquid


Duty

Temperature 180 C

Pressure 30 psi


steel plates

Area 1000ft2


Length 1.95m






Length 1.905m









94/204

D. Material Balance

Figure 18. Liquid-Liquid Extraction and Extractive Distillation

Assumptions:






distillation.

Feed = 15,500 kg/hr



Sulfolane = 100170 kg/hr


reference amount for Sulfolane used for aromatics extraction solvent.


95/204

a. Pump 1

M1= M2

M1= 15,500 Kg/Hr

M2= 15,500 Kg/Hr

b. Extraction Column

Basis: Sulfolane Reflux = 42%

Raffinate Recovery = 33%

Feed + Solvent Reflux + Lean Solvent = Raffinate + Rich Solvent

M3= 42,071.4 Kg/Hr

M2+ M3+ M4= M5+ M6

15,500 Kg/Hr + 0.42 (100170 Kg/Hr) + 100,170 Kg/Hr = 0.33 (15500 Kg/Hr) +

M6

Rich Solvent = 152,626.4 Kg/Hr

M6= 152,626.4 Kg/Hr

Raffinate = 5,115 Kg/Hr

M5 = 5,115 Kg/Hr


96/204

c. Condenser 1

M5= M7

M5= 5,115 Kg/Hr

M7= 5,115 Kg/Hr

d. Wash Column

Efficiency = 98% : Heuristics

Assumption: 4,500 Kg/Hr Water Used

Water Wash-To-Water Ratio = 1.75

M9= 1.75 (4,500 Kg/Hr)

M9= 7,875 Kg/Hr

Water + Raffinate = Washed Raffinate + Water Wash

4,500 Kg/Hr + M7= M8+ M9

4,500 Kg/Hr + 5115 Kg/Hr = M8+ 7,875 Kg/Hr

M8= 1,740 Kg/Hr (0.98)

Washed Raffinate = 1,705.2 Kg/Hr

M8= 1,705.2 Kg/Hr


97/204

e. Stripper Column


Basis: Solvent-To-Extract Ratio = 2

Rich Solvent = Extract + Solvent

Rich Solvent = 152,626.4 Kg/Hr

M11= 2(M10)

152,626.4 Kg/Hr = M10+ M11

M10= 50,875.47 Kg/Hr

M11= 101750.93 Kg/Hr (0.95)

M11 = 96,663.38 Kg/Hr

f. Pump 2

M10 = M12

M10= 50,875.47 Kg/Hr

M12= 50,875.47 Kg/Hr

g. Condenser 2

M11= M13

M11= 96,663.38 Kg/Hr

M13= 96,663.38 Kg/Hr


98/204

h. Separator 1

M13= M3+ M14

96,663.38 Kg/Hr = 42071.4 Kg/Hr + M14

M14= 59,679.53 Kg/Hr

i. Water Stripper

Effficiency = 80% : Heuristics

M9+ M14 = M15 + M16

M15= 0.8 (M9)

M9= 7,875 Kg/Hr

M15= 6,300 Kg/Hr

7,875 Kg/Hr + 59,679.53 Kg/Hr = 6,300 Kg/Hr + M16

M16 = 61,254.53 Kg/Hr

j. Pump 3

M15= M17

M15= 6300 Kg/Hr

M17= 6300 Kg/Hr

k. Regenerator



99/204

Basis: 99% Regeneration

M16= M18+ M19

M18= Waste

M18= 1% (M16)

M18 = 612.55 Kg/Hr

M19= (61,254.53 Kg/Hr612.55 Kg/Hr) (0.98)

M19 = 59,429.14 Kg/Hr

Solvent Regenerated = 59,429.14 Kg/Hr

l. Recovery Column

Efficiency = 95 %: Heuristics

Extract = 50,875.47 Kg/Hr

M19 = 59,429.14 Kg/Hr

Water = 6,300 Kg/Hr

Extract + Solvent Regenerated + Water = Aromatics + Lean Solvent

50,875.47 Kg/Hr + 59,429.14 Kg/Hr + 6,300 Kg/Hr = M20+ 100,170 Kg/Hr

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