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5-RECYCL
3-FUEL 7-PROD CONDENSE DISTL2 DISTL1 2-FFLASH FLASH 6-BOT TOM 8-BOT TOM 4-FDIST1
Figure 8. Aspen simulation model for separation section of cumene production. Table 7. Summary of overall result from Aspen Simulation. Stream No. From To Substream: MIXED Phase: Component Mole Flow BENZENE PROPYLEN PROPANE CUMENE P-DIPB Component Mole Fraction BENZENE PROPYLEN PROPANE CUMENE P-DIPB Component Mass Flow BENZENE PROPYLEN KG/HR KG/HR 8511.26 372.83 8511.26 372.83 664.8 286.29 7846.47 86.54 7843.71 86.54 2.75 0 2.75 0 0 0 KMOL/HR KMOL/HR KMOL/HR KMOL/HR KMOL/HR 108.96 8.86 8.06 94.39 2.79 108.96 8.86 8.06 94.39 2.79 8.51 6.8 5.62 0.83 0 100.45 2.06 2.44 93.56 2.79 100.41 2.06 2.44 0 0 0.04 0 0 93.56 2.79 0.04 0 0 93.43 0.03 0 0 0 0.13 2.75 Vapor Mixed Vapor Liquid Liquid Liquid Liquid Liquid CONDENSER Unit 1 2 CONDENSER FLASH 3 FLASH 4 FLASH DISTL1 5 DISTL1 6 DISTL1 DISTL2 7 DISTL2 8 DISTL2
0 0 0 0.971 0.029
0 0 0 0.999 0
0 0 0 0.045 0.955
PROPANE CUMENE P-DIPB Component Mass Fraction BENZENE PROPYLEN PROPANE CUMENE P-DIPB Mole Flow Mass Flow Volume Flow Temperature Pressure Vapor Fraction Liquid Fraction Solid Fraction Molar Enthalpy Mass Enthalpy Enthalpy Flow Molar Entropy Mass Entropy Molar Density Mass Density Average Molecular Weight
107.73 0 0
0 11245.26 452.27
0 11229.75 5.64
0 15.5 446.63
0.405 0.018 0.017 0.539 0.022 KMOL/HR KG/HR L/MIN K BAR 223.06 21037.4 6367.44 623.15 30.25 1 0 0 GJ/KMOL CAL/GM GJ/HR CAL/MOL-K CAL/GM-K MOL/CC GM/CC 0.09 234.68 20.67 -45.96 -0.49 0 0.06 94.31
0.405 0.018 0.017 0.539 0.022 223.06 21037.4 6674.74 363.18 1.75 0.1 0.9 0 0.01 36.99 3.26 -81.64 -0.87 0 0.05 94.31
0.512 0.22 0.191 0.077 0 21.76 1299.14 6259.2 363.18 1.75 1 0 0 0.02 69.6 0.38 -40.67 -0.68 0 0 59.69
0.398 0.004 0.005 0.57 0.023 201.3 19738.26 415.54 363.18 1.75 0 1 0 0.01 34.84 2.88 -86.07 -0.88 0.01 0.79 98.06
0.976 0.011 0.013 0 0 104.91 8037.99 161.92 329.71 1.6 0 1 0 0.05 152.16 5.12 -56.88 -0.74 0.01 0.83 76.62
0 0 0 0.961 0.039 96.38 11700.28 271.16 448.95 1.75 0 1 0 -0.01 -11.44 -0.56 -111.06 -0.91 0.01 0.72 121.4
0 0 0 0.999 0.001 93.5 11238.14 259.74 446.72 1.7 0 1 0 0 -8.36 -0.39 -109.73 -0.91 0.01 0.72 120.19
0 0 0 0.034 0.966 2.88 462.13 11.32 505.51 1.85 0 1 0 -0.06 -82.77 -0.16 -162.1 -1.01 0 0.68 160.39
m h P ! m c c pc (Tcb Tca ) ! q
Where m h = rate of condensation of vapor and P = latent heat of vaporization of vapor. Flash Drum
V ! VoF * F L ! F V dV Sh ! F1 F2 dt M F ( xi C pi ) Q ! M D ( xi C pi ) M D P M B ( xi C pi )
Distillation Column
F ! DB
F xF ! D x D B x B
F H F q r ! D H D B H B qc
93.2117430 93.2117429 93.2117429 93.2117428 93.2117428 93.2117427 93.2117427 93.2117426 93.2117426 3 4 0.4 0.5 0.6 0.7 Tray Spacing (m) Figure 10. Effect of tray spacing on the amount of cumene produced for different type of tray for Distillation 1. 0.3
bubble cap sieve Valve
Tray diameter (m) Figure 9. Effect of tray diameter on the amount of cumene produced for different type of tray for Distillation 1.
93.2117432 93.2117431 Cumene (kmol/hr) 93.2117431 93.2117430 93.2117430 93.2117429 93.2117429 4 0.2 0.3
2 3 Tray diameter(m)
0.7
Figure 11. Effect of tray diameter on the amount of cumene produced for different type of tray for Distillation 2.
Figure 12. Effect of tray spacing on the amount of cumene produced for different type of tray for Distillation 2.
24-inch spacing of sieve tray would contribute to a lower value of capital cost.
1 0.9
Cumene Purity Benzene in Fuel Gas
360
365
370
98
100
102
104
106
108
110
Temperature (K) Figure 13. Sensitivity analysis of mol or weight fraction as a function of Temperature.
Distillate Rate Distillation 1 (kmol/hr) Figure 14. Sensitivity analysis of mol or weight fraction as a function of distillate rate of Distillation 1.
1 0.9 Fraction (mol or weight) Fraction (mol or weight) 0.8 0.7 0.6 0.5 0.4 0.3 0 10 20 30 40 Feed Stage Distillation 1 Figure 15. Sensitivity analysis of mol or weight fraction as a function of feed stage of Distillation 1.
1 0.9 0.8
Cumene Purity
30
40
Feed stage Distillation 2 Figure 16. Sensitivity analysis of mol or weight fraction as a function of feed stage of Distillation 2.
94
96
98
Distillate Rate Distillation 2 (kmol/hr) Figure 17. Sensitivity analysis of mol or weight fraction as function of distillate rate of Distillation 2.
Design Optimization - NPV (Net Present Value) Analysis Simplified Economic Analysis NPV ! C I Where: CI = Initial capital investment N = Total project lifetime (assume 15 years) R = Receipts (product sales) X = Operating costs I = Bank interest rate (assume 10%) t = Tax Rate based on combined Federal and State rate (assume 40.1%)
R X
j 1 t
1 i
j j !1
n
800000 700000 600000 500000 Cost ($/yr) 400000 300000 200000 100000 0 0.2 0.7 1.2 1.7 2.2 2.7 Reflux Ratio Figure 18. Fixed Cost, Labor Cost, and Utility Cost as a function of Reflux ratio related to number of stages (From Figure 2) for Distillation 1 3.2 3.7 4.2 4.7 5.2
Fixed Cost Utility Cost
Labor Cost
250000
200000
Fixed Cost Utility Cost
Cost ($/yr)
150000
Labor Cost
100000
50000
0 0.12 0.14 0.16 0.18 0.2 0.22 0.24 0.26 0.28 0.3 Reflux Ratio Figure 19. Fixed Cost, Labor Cost, and Utility Cost as a function of Reflux ratio related to number of stages (From Figure 2) for Distillation 2
Appendix V
Detailed calculation 1. Flash drum area calculation
Table 8. Parameter values for flash drum.
Average Density MWl ! xi * MWi MWv ! yi * MWi Specific Volume Vl ! Density MWl Vl P * MWv Vv ! R * Tdrum Vl ! Permissible vapour velocity (Based on Blackwell Equation) Wv ! V * MWv Wl ! L * MWl Flv ! Vv Wl * Vl Wv
2
xi * MWi Vi
Vl Vv Vv
V * MWv Uperm * Vv
4* A 4
H ! 3* D
2. Condenser area calculation (From Perry, 7th Edition) Assuming shell and tube heat exchanger q Uo(TLM (T 1 (T 2 (Th 2 Tc1) (Th1 Tc 2) ! (TLM ! (Th 2 Tc1) (T 1 ln ln (Th1 Tc 2) (T 2 A! Uo ! 709.78291764 3. Reboiler area calculation (MSH, 7th Edition) Assuming Kettle reboiler A! q W 0.15 * P * VV * ? * g * ( VL VV )A4 Parameter values (From Perry, 7th Edition):
1 2 1
W m 2 0C
6.286 A0 5.349 A0
K K
cumene benzene
ab=
( a+
b)
Chapman-Enskog equation (BSL 2nd Edition) The feed to the first distillation column contains five components- benzene, propylene, propane, cumene and p-DIPB. The distillate contains mostly benzene while the bottom is dominated with cumene. In calculating for the gas diffusivity, we can simplify the interaction of the particles to simply between the cumene and benzene.
Other Calculations
mi: slope of the equilibrium curve Equilibrium and operating line are of similar slope. Assume =1
Correct resulting tray efficiency for the effect of entrainment by Colburns equation
For the calculation of the efficiency of the second distillation column, the same equations are utilized; however several parameters have different values now:
a= b=
8.75 A0 6.286 A0
K K
p-DIPB cumene
EMV Ea
REFERENCES Bird, R. B., Stewart, W. E., & Lightfoot, E. N. (2007). Transport phenomena. New York, N.Y.: J. Wiley. Chemical engineering. (n.d.). Retrieved from http://www.che-digital.com/che/201004#pg1 Hodge, S. A. (2008). U.s. states lead the world in high corporate taxes. Retrieved from http://www.taxfoundation.org/publications/show/22917.html ICIS Chemical Business, http://www.icis.com/Home Luyben, W.L (2010). Design and Control of the Cumene Process, Industrial & Engineering Chemistry Research, 49(2), pp 719734. Retrieved March 13, 2010, from Applied Science Full Text database. McCabe, W. L., Smith, J. C., & Harriott, P. (2005). Unit operations of chemical engineering. New York, N.Y.: McGraw Hill. Perry, R. H. (1997). Perrys chemical engineers handbook. New York, N.Y.: McGraw-Hill. Turton, R., Bailie, R.C., Whiting, W.B., and Shaeiwitz, J.A. (1998). Analysis, synthesis, and design of chemical processes. Upper Saddle River, N.J.: Prentice Hall.