During the production of metallurgical coke a by-product gas stream is produced

which contains a complex mix of hydrocarbons, including alkylaromatics. You are

currently working for a company involved in assisting a Chinese coke manufacturer
with assessing the potential for converting the gas into high value chemicals. Your
team is tasked with assessing the potential for producing high purity benzene (>97
wt%) from the alkylaromatics. As a starting point your manager has asked you to
examine only the hydrodealkylation of toluene to benzene according to the following
reaction:

C
6
H
5
CH
3
+ H
2
C
6
H
6
+ CH
4


Your manager wants you to establish a process flowsheet for the production of
benzene from toluene, build a working model in ASPEN to solve the mass and energy
balances for the process, and then carry out an in-depth analysis of the process to
determine a range of performance related issues.

Given the size of the coke plant and production rate of by-product gas a basis of
55,000 tonnes of benzene product per annum has been established as a basis for the
assessment. The coke plant also generates a hydrogen rich gas stream containing 10
% (by volume) methane, which could be used as the source of hydrogen needed. If
the results from your team indicate that the potential for benzene production is good,
the results from your project will be extended to include the full range of
alkylaromatics in the gas.

1.1 Objectives and Aims
Recovery of valuable material is important in ensuring maximum utilization of
resources. This report aims to assess the recovery of benzene from by-product gas.
Table XX lists the scope of the report.
In Scope Out of Scope
Production of benzene from toluene Catalyst regeneration (2 reactors, single
standby
Comparison of available production
technologies
Cost to replace catalyst (very long
lifespan
Modeling of selected process in aspen Source of steam
Optimization of selected process *
Economic analysis Separation of other hydrocarbons from
by-product gas stream

1.1 Raw Materials and Products pg
a Raw materials, end uses

1.2 Alternative Technologies 2 pg
b BFD, Alternative Tech
1.3 Process Flow Diagram 1 pg
c PFD
1.4 System Structure 2 pg
d Identify the system structures, the major units in the process, their function and why
they are connected as they are for the chosen process. Identify where heat is being
generated and consumed within the process (which units) and where heat integration
takes place

Structure of the HDA system consists of several major unit operations, discussed
below.
1.4.1 System Structure
The process essentially manipulates the reaction between toluene and hydrogen to
produce benzene, given by the following equation;

The process is constructed revolving this reaction, its kinetics and thermodynamics.
The first phase of the process prepares reactant streams for the reaction, which
includes raising the streams to the required temperature and pressure. The second
phase is the reaction, and the last phase is separation of product from the reactor
output stream. A more detailed process description is discussed below.
functions
arrangement justification
input info
design steps calc needed, dot points
key output
1.4.2 Stream Preparation
Fresh input streams are mixed with recycle streams fresh toluene feed (S03) with
recycle toluene feed (S27), fresh hydrogen feed (S05) with recycle hydrogen feed
(S07) in mixing tanks M001 and M009 respectively. These streams are then mixed in
the mixing tank M002 before passed through heat exchanger H001 to raise its
temperature to 600C, and pressure to 24.81 bar.
1.4.2 Reactor
90% conversion
exothermic
600C
20 to 60 bar
catalyst - ?
side reaction


1.4.3 Flash Drum Separator
1.4.4 Distillation Column
1.4.5 Heat Exchanger
1.4.6 Process Units Connection pg
1.4.7 Heat Integration pg
Reactor and recycle T P to maximize benzene and minimize biphenyl formation.
Both hydrogen and toluene needs to be pressurized before entering reactor.
Will need furnace.

1.5 Process Goals 1 pg
Identify the goals (technical, economic, operational, health and safety, environmental)
of the process and where goals are competing Your team is tasked with assessing the
potential for producing high purity benzene (>97wt%) from the alkylaromatics

basis of 55,000 tonnes of benzene product per annum


1.6 Operating Conditions pg
1.6.1
1.6.2
1.6.3
1.6.4

Provide key operating conditions for the units within the process, explaining the
significance of those operating conditions


1.7 Hazards and Risks 1 pg
g Hazards Risk
1.8 World Trends 1 pg
h World Trends