Plant Design 1 Project Report

Conventional Ethylene Process
Case Study: Preliminary Design
November 30th, 2012
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
the same amount of ethylene (Peters,2003).
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2. Introduction
Ethylene is a product in high demand throughout the petrochemical industry, as it
has a wide variety of applications. Production of ethylene is known to occur through
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
hydrocarbon are polymerization, oxidization, and halogenation. By going through these
processes, ethylene can be transformed into plastics, automotive anti-freeze, or PVC
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.
This case study demonstrates an ethylene plant which is designed to produce up
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,
compression, acid gas removal, drying, deethanization, and acetylene hydrogenation
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
thriving company. To ensure the safety of employees as well as the surrounding
community, a HAZOP study is included for all areas of the process that was simulated.
Along with the completion of a HAZOP study, implementation of personal protective
equipment is required. Other protection devices such as emission detectors, noise
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
design case study.
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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
was necessary to obtain the necessary material balance of the plant.
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
determined based on calculations in the plant design textbook.
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
were designed for the protection of the community.
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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
for both chemicals are as follows:
Ethane to ethylene:
C2H6 ↔ C2H4 + H2
Propane to ethylene & propylene:
C3H8 ↔ C2H4 + CH4
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.
Figure 4.2.a: Steam cracking of Ethane to Ethylene.
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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
desired compositions of ethylene and propylene.
4.2.ii Acetylene Reactor
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-
spec product into the product line.
Primary reaction chemistry of ethane to ethylene:
C2H2 + H2↔ C2H4
Secondary reaction chemistry turns ethylene to ethane:
C2H4 + H2 ↔ C2H6
4.2.iii Methylacetylene & Propadiene (MAPD) Reactor
This reactor was not modeled in the simulation; however, the reaction chemistry is still
very important and is vital for discussion.
Primary reaction chemistry to propylene:
C3H4 + H2 ↔ C3H6
Secondary reaction propylene to propane:
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.
H2S + 2NaOH  Na2S + H2O
CO2 + 2 NaOH  Na2CO3 + H2O
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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
Economics of Chemical Engineering, 5th edition, chapter 3.
4.3.i - Quenching Section
Figure 4.3.a – Process Flow Diagram for the Cracking Section
(Figure 3-8 in Plant Design & Economics textbook)
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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
Figure 4.3.b – Process Flow Diagram for the Quenching Section
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Table 4.3.b - Quenching Section Initial Parameters
QUENCHING SECTION
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
COMPRESSION AND ACID GAS REMOVAL SECTION

PRIMARY EQUIPMENT
C-301 CONDENSATE STRIPPER 323 - -
324 63 234
325 - -
K-301 FIRST STAGE COMPRESSION 202 39 131
301 81 234
K-302 SECOND STAGE COMPRESSION 304 35 221
305 82 448
K-303 THIRD STAGE COMPRESSION 307 33 434
308 91 975
K-304 FOURTH STAGE COMPRESSION 329 37.6 931
330 88 1813
V-301 KNOCKOUT DRUMS 303 35 221
316 - -
320 35 221
304 35 221
319 35 221
V-302 KNOCKOUT DRUMS 312 - 434
306 33 434
314 33 434
307 33 434
315 33 434
V-303 KNOCKOUT DRUMS 309 38 962
326 38 962
310 38 962
311 38 962
C-302 CAUSTIC SCRUBBER 326 38 962
327-328 - -
329 37.6 931
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Table 4.3.c - Compression and Acid Gas Removal Initial Parameters (continued)
COMPRESSION AND ACID GAS REMOVAL SECTION (Continued)

SECONDARY EQUIPMENT
E-301 REBOILER - - -
E-302 EXCHANGER 302 - 234
303 35 221
E-303 EXCHANGER 305 82 448
306 33 434
E-304 EXCHANGER 308 91 975
309 38 962
P-303 PUMP 319 35 221
323 - -
P-304 (A-B) PUMP 328 - -
P-305 (A-B) PUMP 327 - -
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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
DRYING, DEETHANIZATION & ACETYLENE HYDROGENATION REMOVAL SECTION

PRIMARY EQUIPMENT
D-401 (A-B) GAS DRYERS 403 13 1792
408 13 1792
S-401 WATER DECANTER 404 13 1792
405 13 1792
406 13 1792
D-402 (A-B) LIQUID DRYERS 406 13 1792
407 13 1758
C-401 PRIMARY DEETHANIZER 407 13 1758
411 -12 1744
413 89.8 1765
C-402 DEETHANIZER COLUMN 414 - -
415 -60 1709
416 49 1744
K-401 FIFTH-STAGE COMPRESSOR 417 27 1703
418 90 3591
R-401 ACETYLENE REACTOR 419 79.4 3577
420 94 3557
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Table 4.3.d - Drying, Deethanization and Acetylene Hydrogenation Initial Parameters
(Continued)
DRYING, DEETHANIZATION & ACETYLENE HYDROGENATION REMOVAL SECTION

SECONDARY EQUIPMENT
E-401 (A-B) EXCHANGER 330 88 1813
401 33 1803
E-402 EXCHANGER 401 33 1803
402 13 1792
E-403 EXCHANGER 408 13 1792
603 -7 2047
409 - -
410 -2 2033
E-404 EXCHANGER 409 - -
411 -12 1744
E-405 CONDENSER 412 -12 1744
414 - -
E-406 REBOILER LIQUID 89.8 1765
BOTTOMS
413 89.8 1765
E-407 CONDENSER VAPOR GAS -60 1709
415 -60 1709
E-408 REBOILER LIQUID 49 1744
BOTTOMS
416 49 1744
E-409 EXCHANGER 415 -60 1709
420 94 3557
417 27 1703
421 15 3544
E-410 EXCHANGER 418 90 3591
419 79.4 3577
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4.4 Raw Materials
Raw materials:
70/30 Ethane/Propane mixture (feedstock)
Caustic (100% basis)
Feedstock:
Inlet temperature: 41 °C
Inlet Pressure: 1709 kPa
Composition:
Ethane: 70 wt%
Propane: 30 wt%
Flow rates:
Overall flow rate: 90,000 kg/hr
Ethane flow rate: 63,000 kg/hr
Propane flow rate: 27,000 kg/hr
Phase:
Liquid phase at inlet required
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4.5 Design of Major Process Equipment
4.5.i Heat Exchangers & Condenser
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°.
C3 Refrigeration Exchangers (E-402, E-404, & E405) has 3 grades of
temperatures. The C3 Refrigeration is allowed to vaporize as necessary to provide duty
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
assumed to have a contingency value of a quarter of a million dollars.
E-403 & E-409 were designed based on the flows necessary for the main
process stream outlet temperature to meet the temperature spec.
E-202, E-205, & E-301 were contingencies in the total exchanger costs as the
exchangers were not simulated.
4.5.ii Pressure Vessels
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
volume metric flow rate into the vessel.
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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
column is designed to separate the maximum about of C3 and heavier components
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
to C-604 will not bring the propylene product offspec.
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.
Sizing each compressor required the network.
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
was sized and costs based a $/flow rate basis.
4.5.vii Dryers
D-401(A&B) and D-401(A&B) were designed to separate any water left in the process
flow. They were modeled as separates to effectively remove the water.
4.5.ix Pumps
P-201, P-202, P-304, and P-305 were not simulated, but the streams that were there
inputs were used to size the pumps
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4.5.x Separators
The separators were sized based on the method found in the referenced Coulson and
Richardson’s Chemical Engineering textbook. A value for theta was calculated to
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.
Finally, the diameter and the height were found.
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4.6 Operating Labor Requirements
The operating labor economics, found in section 5.12, were based on the following
assumptions:
 Plant operation: 350 days/yr
 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
by this method had to be brought to an approximate present value in 2010.
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
methods of calculating overall prices were not defined.
Table 5.a - Fixed Capital Investment Breakdown
Investment Items Cost
Purchased equipment, E $66,420,643

Purchased-equipment installation, 0.47E $31,217,702
Instrumentation and control, 0.36E $23,911,431
Piping (installed), 0.68E $45,166,037
Electrical (installed), 0.11E $7,306,271
Buildings (including services), 0.18E $11,955,716
Yard improvements, 0.1E $6,642,064
Service facilities (installed), 1.05E $69,741,675
Total direct plant cost, D $262,361,538
Engineering and supervision, 0.33E $21,918,812

Construction expenses, 0.41E $27,232,463
Legal expenses, 0.04E $2,656,826
Total direct and indirect costs, D+I $314,169,639
Contractor's fee, 0.05*(D+I) $15,708,482
Contingency, 0.1*(D+I) $31,416,964
Fixed-capital investment (2010 FCI) $361,295,085
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Table 5.b - Purchased Equipment Cost
Equipment Type Purchased cost
Heat exchangers and Condensers $2,326,921

Pressure vessels $1,658,577
Columns and trays $11,559,075
Compressors $20,499,642
Furnaces $28,339,269
Reactors $922,337
Dryers $445,564
Pumps $210,745
Separators $458,512
Present Value (2010) Total $66,420,643
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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.
Cold service is defined as a system using C3-refrigeration or runs at or below 20°C. In
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
Shell Tube Related

Block ID Area[m2] Material Type Cost
Pressure Pressure Information
E-101 Contingency A-C $150,000

E-102 565 450 65.94 SS Floating Head LP Steam $28,028
E-103 8650 170 257.27 TLE
E-201 172 165 87.56 CS Floating Head A&B $22,520
E-202 Contingency A&B $100,000
E-203 450 152 310.01 CS Floating Head A-D $111,716
E-204 450 152 290.25 CS Floating Head A-D $106,572
E-205 Contingency Reboiler $50,000
E-302 450 234 378.58 CS Floating Head CW $32,172
E-401 450 1844 317.93 CS Floating Head CW (A&B) $76,788
E-402 790 1803 213.45 SS Floating Head C3 Ref $85,166
E-403 2047 1792 64.68 SS Floating Head Ethane $37,229
E-404 330 1792 151.32 SS Floating Head C3 Ref $66,026
E-405 110 1744 0.65 SS Spiral Tube C3 Ref $7,697
E-407 Contingency Condenser $250,000
E-409 1709 3557 90.08 SS Fixed Tube Exchanger $19,620
E-410 450 3591 29.65 CS Fixed Tube CW $6,210
2002 Cost Total $1,760,279
2010 Cost Total $2,326,921
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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
Volume [m3] 7362.68
Cost (2002) $379,417
Block V-303
Parameter / Stream 309
Volume Flow [m3/hr] 33876.32
Volume [m3] 2258.42
Cost (2002) $137,276
Block V-401
Parameter / Stream 402
Volume Flow [m3/hr] 70297.58
Volume [m3] 4686.51
Cost (2002) $279,266
2002 Cost of Pressure Vessels $1,254,687
2010 Cost of Pressure Vessels $1,658,577
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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
of the quench tower.
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
cost of the column to the cost of the packing.
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
34 | P a g e
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
overall cost was obtained.
For information related to the columns see Table 5.3.a.
Table 5.3.a - Sizing and Cost of Columns & Trays
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
2010 Total Cost of all Columns and Packing/Trays $11,559,075
35 | P a g e
Table 5.3.b - Parameters & Cost of Column C-201A
C-201A
Parameters / Streams 201B-A 204
Volume Flow [m3/hr] 246363.59 643.77

Total Flow In [m3/hr] 247007.36
Volume [m3] 16467.16
2002 Value
$720,133
2010 Value
$951,947
Table 5.3.c - Parameters & Cost of Column C-201B
C-201B
Parameters / Streams 201C-B 205 HCA-B RFLXA-B
Volume Flow [m3/hr] 242672.91 303.61 647.96 0
Volume [m3] 16241.63

2002 Value $711,694
2010 Value $940,792
36 | P a g e
Table 5.3.d - Parameters & Cost of Column C-201C
C-201C
Parameters / Streams 201D-C 206 HCB-C RFLXB-C
Volume Flow [m3/hr] 248096.61 210.71 961.03 0
Volume [m3] 16617.89

2002 Value $725,774
2010 Value $959,404
Table 5.3.e - Parameters & Cost of Column C-201D
C-201D
Parameters / Stream RFLXC-D 203B 201
Volume Flow [m3/hr] 0 1156.24 188322.02

Volume [m3] 12631.88
2002 Value $576,606
2010 Value $762,218
37 | P a g e
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
driving force for the compressors.
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
page in Figure 5.4.a and Figure 5.4.b.
38 | P a g e
Figure 5.4.a - Simulated Compressor Input
Figure 5.4.b - Simulated Compressor Net Work
39 | P a g e
Table 5.4.a: Economics of Compressors
Block K-301
Net Work required [kW] 4715.92

2002 Centrifugal-Turbine Cost $2,907,119
Block K-302

Block K-303

Block K-304

Block K-401

2002 Total Cost of CGC $15,507,654
2010 Total Cost of CGC $20,499,642
40 | P a g e
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 tubes used were made of chrome/moly tubes.
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.
Table 5.5.a - Parameters & Cost of Furnaces
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
Cost of 8 Furnaces in 2010 $28,339,269
41 | P a g e
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
the reactors is listed in Table 5.6.a.
Table 5.6.a - Parameters & Cost of the Reactor
R-401
Ch. 3 Cost of Reactors $551,000

Ch. 3 Flow Rate [kg/hr] 196380.00
Simulated Flow Rate [kg/hr] 140281.77
Calculated Cost in 2000 $393,600
Flowrate to Acetylene Reactor [kg/hr] 122816.14
Calculated Cost of Acetylene Reactor $344,595
Assume 2 Reactors $689,190
2010 Total Cost $922,337
42 | P a g e
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.
Table 5.7.a - Sizing and Cost of Dryers
Assume 3 Dryers Gas Assume 3 Dryers Liquid

Parameters of Equipment
Dryers Dryers
Mass of Water (kg/hr) 122.82 1.19

Time to fill Dryer (hrs) 48 72
kg Desicant per kg water 12.5 12.5
Volume of dryer per kg desicant 0.0115 0.0116
Volume of Dryer ( m3) 847.72 12.35
Height (m) 60 10
Area (m2) 14.13 1.24
Cost (2002 value) $82,557 $29,797
Subtotal (2002 value) $337,062
2010 Present Value Cost $445,564
43 | P a g e
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
pertaining to pumps, see Table 5.8.a.
Table 5.8.a - Sizing and Costs of Pumps
Vol Vol Discharge Discharge

Block
Quantity Flowrate Flowrate Pressure Press*Vol 2002 Value 2010 Value
ID
[m3/hr] [m3/s] [kPa] Flow
P-201 A&B 1.17E+03 3.24E-01 152 49.30 $34,582 $91,428

P-202 A 6.38E+01 1.77E-02 538 9.53 $9,525 $12,591
P-303 A Contingency $25,000 $33,048
P-304 A&B 1.93E+01 5.36E-03 935 5.01 $6,772 $17,904
P-305 A&B 9.02E-01 2.51E-04 935 0.23 $21,096 $55,774
Total Equipment Cost $96,975 $210,745
44 | P a g e
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
cost. Information on these separators as discussed is displayed in Table 5.9.a.
Table 5.9.a - Sizing & Cost of Separators
S-401
Diameter [m] 0.9774

Cost (2002) $172,866
Cost (2010) $228,512
S-201
Contingency
Cost (2010) $230,000
Total Cost in 2010 $458,512
45 | P a g e
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
overall total cost.
46 | P a g e
Table 5.10.a – Raw Material Economics
Propane
Flowrate [kg/hr] 1000

Volumetric Flowrate [m3/hr] 2.372
Density[kg/m3] 421.585
Density[kg/Gal] 1.596
Average Price of Propane in 2012 [$/Gal] 0.8
Cost [$/kg] 0.501
Flow of Propane [kg/hr] 27000
Propane Total cost [$/hr] $13,535
Ethane
Flowrate [kg/hr] 1000

Volumetric Flowrate [m3/hr] 2.571
Density[kg/m3] 388.954
Density[kg/Gal] 1.472
Average Price of Propane in 2012 [$/Gal] 0.28
Cost [$/kg] 0.190
Flow of Ethane [kg/hr] 63000
Ethane Total Cost [$/hr] $11,981
Caustic (100 % basis)
Flowrate [kg/hr] 102.5

Price of Caustic [$/kg] 0.1124
Caustic Total Cost [$/hr] $11.5
Total Cost of Raw Materials [$/hr] $25,527
47 | P a g e
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
section for process flow charts (PFD’s).
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
index values for years 2001 & 2010.
48 | P a g e
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] $10,045,308
49 | P a g e
5.12 Operating Labor
The total annual labor cost was calculated from operating costs, supervision
costs, and laboratory charges. The supervision and laboratory expenses are calculated
from a percentage of the operating labor costs. The operating labor expenses were
calculated from the assumption that there are 15 workers per shift, with two twelve hour
shifts a day. The plant is assumed to be running 350 days out of the year with a total
scheduled downtime of 15 days. The cost of one employee per kilogram of ethylene
produced was required to calculate the operating labor expenses. This value was
obtained from chapter three of Plaint Design and Economics for Chemical Engineers
using a ratio of the cost of one employee per kilogram of ethylene produced in 2000
(Peters, Timmerhaus, West Table 3-11). Using that ratio, the amount of ethylene
produced in the textbook plant, and the amount produced in the simulated plant to
obtained the 2010 cost of one employee per kilogram of ethylene produced. Once this
value was calculated, the operating labor costs was determined based on workers per
shift, hours per shift, operating days per year, and ethylene production. The economic
information for the required operating labor is illustrated in Table 5.12.a.
50 | P a g e
Table 5.12.a – Economics of Operating Labor
Price ($/kg Price for 2010 Price of 2010 Price for

Labor Classification of Operations One Employee Employees
ethylene) [$/yr] [$/hr] [$/yr]
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)
Laboratory Charges - $860,862 $54.19 $1,137,978
TOTAL ANNUAL LABOR COST $7,681,351
51 | P a g e
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
safety is always prioritized. Because employee safety is regarded as the most
important aspect to running an ethylene plant any person entering process areas should
receive safety training and be accompanied by an employee. In addition, all necessary
personal protective equipment should be worn.
6.1 Personal Protective Equipment (PPE)
For the protection of the employee, it is required that the following equipment be
worn while in the process areas:
 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)
52 | P a g e
6.1 Personal Protective Equipment (PPE) (cont.)
In case of emergencies the following equipment should be kept near the process area,
such as control rooms:
 Respiratory Pack
 Hazmat Suits
 Safety Shower
 Fire Extinguisher
 Fire Blankets
53 | P a g e
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.
Table 6.2.a – HAZOP Evaluation of the Process

Equipme Guid
Possible
nt e Propert
Possible Cause Consequen Action Required
Referenc Wor y
ce
e d
All Material
Other leakage, LEL meters around
Operation than
Flow Pipe fracture
possible plant boundaries
al Areas explosion
Vessel runs dry.

No feed to
Flow indicator will read
Valve in stream 104-105 furnace, causing
No Flow low flow and trip
fail/close. downstream
furnace.
equipment
damage
Liquid in vapor
stream (106).
Add Level Alarm and
↓ Level Level indicator malfunction Liquid sent to
possible trip furnace
furnace, causing
V-101 tube rupture
Liquid in vapor
Feedstock stream (106). Level controller will
Drum More Flow Flow indicator misread. Liquid sent to cause inlet valve to V-
furnace, causing 101 to adjust flow
tube rupture
Liquid in vapor
stream (106).
Add secondary level
↓ Level Level indicator misread Liquid sent to
indicator/alarm
furnace, causing
tube rupture
Tank overfills,
Revers Reverse flow from process Check valve is available
Flow reagents
e (106-108) to stop backflow
released
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
54 | P a g e
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
V-101 level alarm

and possibly put
furnace on safe-
No Flow Valve on 104 fails closes Furnace damage mode
Furnace damage
Pluggage in Line 112 due to and possible Flow indicator
↓ ↓ Coke explosion trips furnace
Dilution Flow indicator
↓ steam no flow in line 226 Tube coking alarm
Flow indicator
F-101 alarm sounds on
line 110, Add more
Cracking If minimum is not dilution steam
Furnace met, then tubes until more flow is
Flow controller to V-101 can be available or go into
Less Flow malfunction overheated safe-mode
Interlocks to
Furnace damage prevent regen air
Other Air enters Line 111 under and possible under normal
than Flow normal operations explosion operations
Temperature
Tube damage indicator monitors
and possible tube outlet
More Heat Burning too much fuel explosion temperature
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
S-201 Oil Level Indicator and

No Flow Pluggage in line 207 Damage to P-201 alarm
Separator
More Flow Increase in furnace rates Tank Rupture Level Indicator and
55 | P a g e
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
Equipment Guide Possible Action

Property Possible Cause
Reference Word Consequence Required
No flow in line 202 Flow alarm and Trip

No Flow E-201 pluggage which will damage CGC the unit
Not enough cooling in
C-201. Heavier
molecules can exit to Increase reflux to
↓ Flow E-204 pluggage line 202 promote cooling
Not enough cooling in
C-201 C-201. Heavier
molecules can exit to Increase flows in
Quench ↓ ↓ Line 205 pluggage line 202 line 204
Tower Not enough cooling in
C-201. Heavier
molecules can exit to Increase flow in
↓ ↓ Line 206 pluggage line 202 line 205 and/or 204
Pressure Relief
More Pressure Pluggage on line 202 Rupture of C-201 Valve to Flare
Flow in Line 202 is
High Temperature E-204 pluggage offspec Temperature alarm
No flow into pyrolysis Flow indicator &

No Flow Pluggage on line 212 gasoline line. alarm
S-202 Oil too much level / tank
More Flow Increase rates rupture Add level alarm
Coalescer
add pressure relief
valve, add level
↓ Pressure Overflow Tank rupture indicator
Dry up the tower

C-202 causing no flow in line Add flow indicator
No or Not Flow no flow stream 322 206 and increase reflux
Process
Add pressure relief
Water valve and add flow
Stripper indicator to line
↓ ↓ pluggage on line 206 overpressure unit 206
56 | P a g e
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.

Equipm Guid
ent e Prope Possible
Possible Cause Action Required
Referen Wor rty Consequence
ce d
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.
No or Flow alarm and Trip

K-301 Not Flow Valve on line 202 closes Damage CGC the CGC
Cracked Decrease in furnace Flow alarm and Trip
Gas Less Flow rates Damage to CGC the CGC
Bleeder valve leak or Flow alarm; trip the
Compres ↓ ↓ rupture Damage to CGC CGC and furnace
sors Pressure fluctuation in Add pressure alarm
↓ Pressure line 202 Damage to CGC and trip CGC
No or Flow alarm and Trip

K-302 Not Flow Valve on line 304 closes Damage CGC the CGC
Cracked Too much material Decrease cooling in E-
Gas Less Flow condenses (line 303 Damage to Compressor 302
Bleeder valve leak or Flow alarm; trip the
Compres ↓ ↓ rupture Damage to CGC CGC and furnace
sors Pressure fluxuation in Add pressure alarm
K-303 No or Flow alarm and Trip

Not Flow Valve on line 307 closes Damage CGC the CGC
Cracked
Too much material Decrease cooling in E-
Gas Less Flow condenses (line 306 Damage to Compressor 303
Compres Bleeder valve leak or Trip the CGC, add flow
sors ↓ ↓ rupture Damage to CGC alarm, and trip furnace
57 | P a g e
Pressure fluxuation in Add pressure alarm
Equipm Guid
ent e Prope Possible
Referen Wor rty Consequence
ce d
K-304 No or Flow alarm and Trip the

Cracked Not Flow Line 329 Pluggage Damage CGC CGC
Valve malfunction in
Gas Less Flow line 329 Damage to Compressor Add flow indicator
Compres Pressure fluxuation Add pressure alarm and
sors ↓ Pressure from C-302 Compressor trip CGC
Heavy molecules make

flow into K302 which can
cause vapors to condense
E-302 is not cooling in compressor (ie
V-301
Less Level enough damaged compressor) Add level alarm
Knockout
As well Valve in line 320 Overfill V-301 tank and
Drums as Liquid malfunction1 sending liquids to line 304 Add level alarm
Overpressure in C-301,
Revers causes fluid to back Add level alarm, and
e Flow flow into V-301 Flood V-301 relief to flare if overfill
Heavy molecules make

flow into K303 which can
cause vapors to condense
V-302 E-303 is not cooling in compressor (ie
Knockout Less Level enough damaged compressor) Add level alarm
Drums as well Valve in line 317 Overfill V-302 tank and
as Liquid malfunction sending liquids to line 307 Add level alarm
revers Fluid from V-301 Add level alarm, and
e Flow V-302 overfill returning to V-302 relief to flare if overfill
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
58 | P a g e
Equipm Gui
ent de Proper Possible
Referen Wor ty Consequence
ce d
Increase process water Add level alarm and

More Flow flow rate in line 327 Flood column control valve
Sending CO2 and H2S
C-302 into downstream
Caustic systems, which could Add flow indicator,
Scrubber Less Flow P-304 pump malfunction damage units. switch to spare pump
Concentration of NaOH
increases and possible Add flow indicator,
↓ ↓ P-305 pump malfunction damage to tray interiors switch to spare pump
Run both units parallel,

and when production
D-401 Production rates rates decrease can go
More Flow increase line 403 Inadequate drying back to using one dryer.
Gas Tempera Sending higher
Dryers ↓ ture E-402 malfunction saturated product Add temperature alarm
Add pressure relief
↓ Pressure Line 408 plugs Unit rupture valve
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
Run both units parallel,

D-402 and when production
Production rates rates decrease can go
Liquid More Flow increase line 406 Inadequate drying back to using one dryer.
Dryers Add pressure relief
↓ Pressure line 407 plugs Unit rupture valve
59 | P a g e
Equipm Guid
ent e Proper Possible
ce d
Tempera E-404 not cooling Downstream composition

More ture enough fluxuations Temperature alarm
Add pressure relief
valve and pressure
↓ Pressure line 412 pluggage Over-pressure in C-401 alarm
Tempera E-406 increases steam Downstream composition
C-401 ↓ ture flow rate fluxuations Temperature alarm
Primary Tempera E-406 decreases steam Downstream composition
Deethan Less ture flow rate fluxuations Temperature alarm
Tank runs dry and sending
izer
Increase flow rate in c2 product into propylene
↓ Level line 413 column add level alarm
↓ Level Line 411 pluggage Tank runs dry add level alarm
Change in flow rate in line
As well Feed composition 413 and 414 and can Adjust flow rates and
as Flow change fluxuate downstream units tank level
Tempera E-405 not cooling Downstream composition

More ture enough fluxuations Temperature alarm
Add pressure relief
valve and pressure
↓ Pressure E-407 pluggage Over-pressure in C-402 alarm
Tempera E-408 increases steam Downstream composition
C-402 ↓ ture flow rate fluxuations Temperature alarm
Deethan Tempera E-408 decreases steam Downstream composition
izer Less ture flow rate fluxuations Temperature alarm
Tank runs dry and sending
Column
Increase flow rate in c2 product into propylene
↓ Level line 416 column add level alarm
↓ ↓ Line 414 pluggage Tank runs dry add level alarm
Change in flow rate in line
As well Feed composition 415 and 416 and can Adjust flow rates and
as Flow change fluxuate downstream units tank level
60 | P a g e
Equipm Guid
ent e Proper Possible
ce d
Flow alarm, Trip CGC and

flare material until
No Flow Pluggage on line 418 Damage to compressor pluggage is resolved
K-401 Possible formation of
Fifth- Temperat liquids,and/or offspec
stage Less ure E-409 Malfunction temperature to R-401 Add temperature alarm
Compres Heavy components in
overhead stream
sor
causing damage to
As well Compositi compressor if Temperature alarm and
as on Malfunction of C-402 condensed into liquids trip unit if necessary
No Flow E-410 pluggage Tank runs dry Add flow indicator

Increase in Increase temperature
More Flow production rates Final product is offspec into reactor
R-401 Temperat E-401 low cooling Increase in ethylene
Acetylen ↓ ure water rate conversion Add temperature alarm
e Reactor Temperat E-401 low cooling
↓ ure water rate Runaway reaction Add temperature alarm
Low acetylene
Temperat E-401 high cooling conversion leading to
Low ure water flow rate offspec final product Add temperature alarm
61 | P a g e
7. Environmental
This proposed ethylene process has been designed in compliance with EPA
(Environmental Protection Agency) and OSHA environmental regulations.
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
for this process.
7.1 Emissions and Effluents Control
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
community to help monitor emission levels.
Table 7.1.a - Emission Limits for Specific Components
Components Maximum Emission Limit

(mg/Nm3)
Carbon monoxide 150.0
Carbon dioxide -
Hydrogen sulfide 5.0
1,3-butadiene -
Benzene 5.0
Toluene 100.0
Xylene 100.0
Sulfur Oxides 850.0
Nitrogen Oxides (Gaseous) 150.0
62 | P a g e
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.
63 | P a g e
7.3 Noise Level Control
This process has been designed to follow EPA and OSHA noise level standards. The
environment as well as the surrounding community can be impacted by the excessive
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
recommended to be placed in the surrounding community to avoid any noise impacts.
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
Air coolers 87-94 Aerodynamic fan blades; decrease in rpm and

increase in pitch; tip and hub seals; decrease
in pressure drop.
Compressors 90-120 Installed mufflers on intake and exhaust,

enclosed machine casings, vibration isolation,
and lagging of piping systems.
Electric motors 90-110 Acoustically lined fan covers, enclosures, and

motor mutes.
Heaters and Furnaces 95-110 Acoustic plenums, intake mufflers, ducts lined
and damped.
Valves <80-108 Avoidance of sonic velocities, limited pressure

drop and mass flow, replacement with special
low-noise valves, vibrations isolation, and
lagging.
Piping 90-105 In-line silencers, vibration isolation and lagging.
Table 7.3.a is copied from the Peters, Timmerhaus, & West Plant Design and Economics for
Chemical Engineers textbook. This book is referenced in section 10.
64 | P a g e
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
available to the public and will be kept updated to best of knowledge.
We as a company adhere to the heuristics set out by the American Institute of
Chemical Engineer’s (AIChE).
65 | P a g e
9. Conclusion
With ethylene products in high demand throughout the petrochemical industry as
well as in a wide variety of applications, efficiency in producing ethylene is imperative.
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.
To ensure safety and environmental-friendliness, HAZOP evaluations were
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
should be kept available in all process areas.
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
66 | P a g e
10. References
Cost Estimator. McGraw Hill. 2003. December 2, 2012.
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/
Green Planet Solar Energy.com. “Ethane: Production and Properties”. 2012
http://www.green-planet-solar-energy.com/ethene.html
Peters, Timmerhaus, West. Plant Design and Economics for Chemical Engineers. New
York: McGraw Hill. 2003. Fifth Edition.
Sinnot, R.K., Coulson and Richardson’s Chemical Engineering. Butterworth-
Heinemann. 2003. Third Edition.
World Bank Group. “Petrochemicals Manufacturing”. 1998.
http://www.ifc.org/ifcext/enviro.nsf/AttachmentsByTitle/gui_petrochem_WB/$FILE
/petrochm_PPAH.pdf
67 | P a g e
11. Appendix
< This section discusses >
11.1 Appendix A: Economic Calculations
Figure 11.1.a: Summary of purchased equipment cost for the ethylene process
Figure 11.1.b: Fixed-capital investment estimate
68 | P a g e
Figure 11.1.c: Cost indexes as annual averages
Figure 11.1.d: Marshall & Swift Equipment Cost Index
69 | P a g e
11.2 Appendix B: Raw Material Calculations
Figure 11.2.a: Material, utility, and by-product costs for the base-case ethylene
process.
70 | P a g e
11.3 Appendix C: Equipment Sizing and Pricing
Figure 11.3.a - Block E-103
Figure 11.3.b - Block E-201
71 | P a g e
Figure 11.3.c - Block E-203
Figure 11.3.d - Block E-204
72 | P a g e
Figure 11.3.e - Block E-302
Figure 11.3.f - Block E-303
73 | P a g e
Figure 11.3.g - Block E-304
Figure 11.3.h - Block E-401
74 | P a g e
Figure 11.3.i - Block E-402
Figure 11.3.j - Block E-403
75 | P a g e
Figure 11.3.k - Block E-404
Figure 11.3.l - Block E-405
76 | P a g e
Figure 11.3.m - Block E-409
Figure 11.3.n - Block E-410
77 | P a g e
Figure 11.3.o - Block K-301
Figure 11.3.p - Block K-302
78 | P a g e
Figure 11.3.q - Block K-303
Figure 11.3.r - Block K-304
79 | P a g e
Figure 11.3.s - Block K-401
Figure 11.3.t - Block V-301
80 | P a g e
Figure 11.3.u - Block V-302
Figure 11.3.v - Block V-303
81 | P a g e
Figure 11.3.w - Block V-401
Figure 11.3.x - Block C-201A
82 | P a g e
Figure 11.3.y - Block C-201B
Figure 11.3.z - Block C-201C
83 | P a g e
Figure 11.3.aa - Block C-201D
Figure 11.3.ab - Block C-401 Configuration
84 | P a g e
Figure 11.3.ac - Block C-401 Tray Sizing Specifications
Figure 11.3.ad - Block C-401 Tray Sizing Results
85 | P a g e
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
Table 11.3.a - Block C-401 Stream Results
86 | P a g e
Figure 11.3.ae - Block C-402 Configuration
Figure 11.3.af - Block C-402 Tray Sizing
Figure 11.3.ag - Block C-402 Tray Sizing Results
87 | P a g e
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
Table 11.3.b - Block C-402 Stream Results
88 | P a g e
Figure 11.3.ah - Block D-401 Stream Results
Figure 11.3.ai - Block D-402 Stream Results
89 | P a g e
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
Table 11.3.c - Block ETH-RXTR (Furnace) Yield
90 | P a g e
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
Table 11.3.d - Block PRO-RXTR (Furnace) Yield
91 | P a g e
Figure 11.3.al - Block R-401 Specifications
92 | P a g e
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
Table 11.3.e - Block R-401 Stream Results
93 | P a g e
.
Figure 11.3.am - Stream 201 Cooling Water In/Out
Figure 11.3.an - Stream 204 Cooling Water In/Out
Figure 11.3.ao: Stream 302 Cooling Water In/Out
94 | P a g e
Figure 11.3.ap - Stream 303 Cooling Water In/Out
Figure 11.3.aq - Stream 304 Cooling Water In/Out
Figure 11.3.ar - Stream 401 Cooling Water In/Out
95 | P a g e
Figure 11.3.as - Stream 410 Cooling Water In/Out
Figure 11.3.at - Block E-102 Thermal Results
96 | P a g e
Figure 11.3.au: Separator Sizing Calculations
97 | P a g e
11.4 Appendix D: Operating Utility Costs
Figure 11.4.a: Cost tabulation for selected utilities and labor
11.5 Appendix E: Operating Labor Costs
Figure 11.5.a: Total product cost estimate
98 | P a g e
11.6 Appendix F: Chemical MSDS Sheets
1. MSDS of Hydrogen
a. http://avogadro.chem.iastate.edu/MSDS/hydrogen.pdf
2. MSDS of Carbon Monoxide

a. http://www.airgas.com/documents/pdf/001014.pdf
3. MSDS of Carbon Dioxide

a. http://www.lakeland.edu/AboutUs/MSDS/PDFs/431/Carbon%20Dioxide%2
0(CO2)%20(All%20Brands).pdf
4. MSDS of Hydrogen Sulfide

5. MSDS of Methane
6. MSDS of Acetylene
7. MSDS of Ethylene
8. MSDS of Ethane
9. MSDS of Propadiene/Methylacetylene
10. MSDS of Propylene

11. MSDS of Propane

12. MSDS of 1,3-Butadiene

99 | P a g e
13. MSDS of Isobutene
a. http://www.praxair.com/praxair.nsf/AllContent/BF76AB324D14663985256
A8600815172/$File/p4614d.pdf
14. MSDS of Butene-1

a. http://www.praxair.com/praxair.nsf/AllContent/A64CD963625C3AA985256
A86008095FD/$File/p6214b.pdf
15. MSDS of n-Butane

16. MSDS of Pentane

a. http://www.sciencelab.com/msds.php?msdsId=9927384
17. MSDS of Benzene

a. http://www.cpchem.com/msds/100000068511_SDS_US_EN.PDF
18. MSDS of Toluene

19. MSDS of m-Xylene

20. MSDS of Hexane

a. https://www.sciencelab.com/msds.php?msdsId=9927187
21. MSDS of Nonane

22. MSDS of 50 wt% NaOH

23. MSDS of Water

100 | P a g e

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Conventional Ethylene Process

Case Study: Preliminary Design

November 30th, 2012

the same amount of ethylene (Peters,2003).

Ethylene is a product in high demand throughout the petrochemical industry, as it

has a wide variety of applications. Production of ethylene is known to occur through

hydrocarbon are polymerization, oxidization, and halogenation. By going through these

processes, ethylene can be transformed into plastics, automotive anti-freeze, or PVC

This case study demonstrates an ethylene plant which is designed to produce up

compression, acid gas removal, drying, deethanization, and acetylene hydrogenation

thriving company. To ensure the safety of employees as well as the surrounding

Along with the completion of a HAZOP study, implementation of personal protective

equipment is required. Other protection devices such as emission detectors, noise

design case study.

was necessary to obtain the necessary material balance of the plant.

determined based on calculations in the plant design textbook.

were designed for the protection of the community.

for both chemicals are as follows:

Propane to ethylene & propylene:

C3H8 ↔ C2H4 + CH4

Figure 4.2.a: Steam cracking of Ethane to Ethylene.

desired compositions of ethylene and propylene.

4.2.ii Acetylene Reactor

spec product into the product line.

Primary reaction chemistry of ethane to ethylene:

C2H2 + H2↔ C2H4

Secondary reaction chemistry turns ethylene to ethane:

4.2.iii Methylacetylene & Propadiene (MAPD) Reactor

very important and is vital for discussion.

Primary reaction chemistry to propylene:

Secondary reaction propylene to propane:

H2S + 2NaOH  Na2S + H2O

CO2 + 2 NaOH  Na2CO3 + H2O

Economics of Chemical Engineering, 5th edition, chapter 3.

4.3.i - Quenching Section

Figure 4.3.a – Process Flow Diagram for the Cracking Section

(Figure 3-8 in Plant Design & Economics textbook)

Figure 4.3.b – Process Flow Diagram for the Quenching Section

(Figure 3-9 in Plant Design & Economics textbook)

(Figure 3-10 in Plant Design & Economics textbook)

COMPRESSION AND ACID GAS REMOVAL SECTION

COMPRESSION AND ACID GAS REMOVAL SECTION (Continued)

(Figure 3-11 in Plant Design & Economics textbook)

DRYING, DEETHANIZATION & ACETYLENE HYDROGENATION REMOVAL SECTION

DRYING, DEETHANIZATION & ACETYLENE HYDROGENATION REMOVAL SECTION

70/30 Ethane/Propane mixture (feedstock)

Caustic (100% basis)

Inlet Pressure: 1709 kPa

Overall flow rate: 90,000 kg/hr

Ethane flow rate: 63,000 kg/hr

Propane flow rate: 27,000 kg/hr

Liquid phase at inlet required

4.5.i Heat Exchangers & Condenser

outlet streams were allowed a maximum change of 11°.

C3 Refrigeration Exchangers (E-402, E-404, & E405) has 3 grades of

temperatures. The C3 Refrigeration is allowed to vaporize as necessary to provide duty

assumed to have a contingency value of a quarter of a million dollars.

process stream outlet temperature to meet the temperature spec.

exchangers were not simulated.

4.5.ii Pressure Vessels

volume metric flow rate into the vessel.

column is designed to separate the maximum about of C3 and heavier components

to C-604 will not bring the propylene product offspec.