EBMax Plant

TABLE OF CONTENT PAGE DECLARATION LETTER OF TRANSMITTAL TASK DISTRIBUTION ACKNOWLEDGEMENT SUMMARY LIST OF FIGURES LIST OF TABLES xi xii xiv xvi xvii xviii xxi

CHAPTER 1 PROCESS BACKGROUND 1.1 1.2 1.3 1.4 INTRODUCTION TO THE ETHYLBENZENE APPLICATION PRODUCTION OF ETHYLBENZENE LIQUID-PHASE ALKYLATION FOR PRODUCTION OF ETHYLBENZENE 1.4.1 1.4.2 1.4.3 1.5 CONVENTIONAL AlCl3 PROCESS MONSANTO PROCESS EXXONMOBIL/BADGER ETHYLBENZENE (EBMAX) 1 2 5 5 6 8 11 12 12 16 19 19 20 21 21 23 24 24 25 i

VAPOR-PHASE ALKYLATION FOR PRODUCTION OF ETHYLBENZENE 1.5.1 ALKAR PROCESS 1.5.2 MOBIL-BADGER PROCESS DISCUSSION ON THE PROCESS ALTERNATIVES 1.6.1 1.6.2 1.6.3 1.6.4 1.6.5 CONVENTIONAL AlCl3 PROCESS MONSANTO PROCESS EXXONMOBIL/BADGER ETHYLBENZENE (EBMAX) ALKAR PROCESS MOBIL-BADGER PROCESS

1.6

1.7

MARKET SURVEY 1.7.1 GLOBAL DEMAND FOR ETHYLBENZENE 1.7.2 PROJECTED SUPPLY/DEMAND IN THE NEXT 10 YEARS

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1.7.3 1.7.4 1.8 1.9 1.1

GLOBAL PRODUCER AND SIMILAR PLANT CAPACITY PRICE OF FEED, BY-PRODUCT & PRODUCTS

26 28 29 29 30 30 31 32 32

PLANT CAPACITY PLANT LOCATION OVERVIEW ENVIROMENTAL ISSUES 1.10.1 ENVIRONMENTAL CONCERN 1.10.2 SAFETY CONCERN 1.10.3 HEALTH CONCERN 1.10.4 MATERIAL SAFETY DATA SHEET

CHAPTER 2: PROCESS FLOW SHEETS AND MATERIAL BALANCES 2.1 ECONOMIC POTENTIAL 2.1.1 2.1.2 2.1.3 2.2 2.3 2.4 INTRODUCTION INPUT-OUTPUT STRUCTURE RECYCLE STRUCTURE 44 44 44 47 50 55 59 59 62

PHYSICAL AND CHEMICAL PROPERTIES OF COMPONENTS THERMODYNAMIC PROPERTY PHYSICAL PROPERTY DATA USING ASPEN 2.4.1 VAPOUR LIQUID EQUILIBRIUM (VLE) DATA

2.5

COMPARISON THE DATA BETWEEN THE LITERATURE REVIEW AND THE ASPEN PLUS PROCESS ANALYSIS 2.6.1 PROCESS FLOW DIAGRAM OF EBMAX PLANT (AUTOCAD) 2.6.2 STREAM TABLE 2.6.3 BLOCK FLOW DIAGRAM OF EBMAX PLANT 2.6.4 TEMPERATURE PHASE AND PRESSURE CHANGE 2.6.5 PROCESS MATRIX CONDITIONS (PCM) ASPEN PLUS STIMULATION 2.7.1 ASPEN PLUS FLOW DIAGRAM 2.7.2 CONVERGENCE DATA 2.7.3 STREAM REPORT 2.7.4 BLOCK (EQUIPEMENT) REPORT

2.6

63 63 64 69 70 71 74 74 75 75 79

2.7

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CHAPTER 3: PROCESS DESCRIPTION 3.1 3.2 PROCESS CHEMISTRY OF ETHYLBENZENE PROCESS CHOSEN CONSIDERATION 3.2.1 SAFETY AND ENVIRONMENTAL ISSUES 3.2.2 ECONOMICAL INDICATOR 3.2.3 MARKET RESEARCH 3.2.4 FLEXIBILITY AND CONTROLLABILITY DESCRIPTION OF PROCESS CHOSEN - EBMAX 3.3.1 ALKYLATION REACTION SYSTEM 3.3.2 TRANSALKYLATION REACTION SYSTEM 3.3.3 BENZENE COLUMN 3.3.4 LIGHTS COLUMN 3.3.5 ETHYLBENZENE COLUMN 3.3.6 POLYETHYLBENZENE COLUMN CRITICAL ASSESSMENT ON EBMAX 84 85 85 86 87 87 88 88 88 89 89 89 90 90

3.3

3.4

CHAPTER 4: ENERGY BALANCE AND UTILITY REQUIREMENTS 4.1 4.2 SUMMARY REPORT OF MASS BALANCE AND ENERGY BALANCE UTILITIES 4.2.1 ELECTRICITY 4.2.2 WATER 4.2.3 STEAM UTILITIES COST CALCULATION HIGH & LOW PRESSURE STEAM BOILER HEAT EXCHANGER NETWORK ANALYSIS HEAT AND POWER INTEGRATION 4.6.1 CALCULATION STEPS OF PINCH TECHNOLOGY AREA ESTIMATION OF HEAT EXCHANGERS ANNUALIZED COST OF HEN 94 134 134 134 134 136 137 137 138 140 152 153

4.3 4.4 4.5 4.6

4.7 4.8

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CHAPTER 5: UNIT DESCRIBTION 5.1 CHEMICAL PLANT EQUIPMENT 5.1.1 REACTOR 5.1.2 MASS TRANSFER EQUIPMENT 5.1.3 HEAT TRANSFER EQUIPMENT 5.1.4 AUXILLORY UNITS EQUIPMENT CHOSEN JUSTIFICATION OF EQUIPMENT CHOSEN 5.3.1 REACTOR 5.3.2 MASS TRANSFER EQUIPMENT 5.3.3 HEAT TRANSFER EQUIPMENT 5.3.4 AUXILLORY UNITS 156 156 157 158 160 161 163 163 164 168

5.2 5.3

CHAPTER 6: DETAILED DESIGN OF EQUIPMENT & SPECIFICATION SHEETS 6.1 DETAILED DESIGN OF ALKYLATION REACTOR, R-101 6.1.1 DESIGN BASIS 6.1.2 DESIGN PARAMETERS 6.1.3 DESIGN CRITERIA 6.1.4 DESIGN METHOD 6.1.5 DETAILED DESIGN OF REACTOR 6.1.6 SELECTION OF REACTOR 6.1.7 REACTOR SIZING 6.1.8 MASS TRANSFER EFFECT 6.1.9 HEAT TRANSFER EFFECT 6.1.10 MECHANICAL ENGINEERING DESIGN 6.1.11 ASPEN CALCULATION DATA FOR REACTOR DETAILED DESIGN OF DISTILLATION COLUMN T-102 6.2.1 DESIGN BASIS 6.2.2 DESIGN PARAMETERS 6.2.3 DESIGN CRITERIA 6.2.4 DESIGN CALCULATION 6.2.4.1 DETERMINING MINIMUM TRAYS 6.2.4.2 DETERMINING MINIMUM REFLUX RATIO 6.2.4.3 DETERMINING NUMBER OF EQUILIBRIUM TRAYS 6.2.4.4 DETERMINING ACTUAL TRAYS-PLATE EFFICIENCY 6.2.4.5 DETERMINING FEED-POINT LOCATION 6.2.4.6 DETERMINING THE NET VAPOR VELOCITY AT 6.2.4.7 DETERMINING THE HEIGHT OF THE COLUMN 6.2.4.8 HEURISTICS IN DESIGNING DISTILLATION COLUMN 170 170 172 172 173 174 176 179 183 185 189 189 190 190 191 191 191 193 193 194 194 195 195 198 198 iv
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6.2

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6.2.5

ASPEN DATA FOR DISTILLATION COLUMN T-102 6.2.5.1 TEMPERATURE PROFILE 6.2.5.2 COMPOSITION PROFILE 6.2.5.3 REFLUX RATIO PROFILE

199 199 200 201 201 201 201 201 202 203 203 203 204 204 205

6.3

DISTILLATION COLUMN T-103 6.3.1 DESIGN BASIS 6.3.2 DESIGN PARAMETERS 6.3.3 DESIGN CRITERIA 6.3.4 DESIGN CALCULATION 6.3.4.1 DETERMINING MINIMUM TRAYS 6.3.4.2 DETERMINING MINIMUM REFLUX RATIO 6.3.4.3 DETERMINING NUMBER OF EQUILIBRIUM TRAYS 6.3.4.4 DETERMINING ACTUAL TRAYS-PLATE EFFICIENCY 6.3.4.5 DETERMINING FEED-POINT LOCATION 6.3.4.6 DETERMINING THE NET VAPOR VELOCITY AT FLOODING CONDITION AND THE DIAMETER OF COLUMN 6.3.4.7 6.3.4.8 DETERMINING THE HEIGHT OF THE COLUMN HEURISTICS IN DESIGNING DISTILLATION COLUMN

207 207 209 209 209 209 209 210 211 211 211 212 212

6.4

DISTILLATION COLUMN T-104 6.4.1 DESIGN BASIS 6.4.2 DESIGN PARAMETERS 6.4.3 DESIGN CRITERIA 6.4.4 DESIGN CALCULATION 6.4.4.1 DETERMINING MINIMUM TRAYS 6.4.4.2 DETERMINING MINIMUM REFLUX RATIO 6.4.4.3 DETERMINING NUMBER OF EQUILIBRIUM TRAYS 6.4.4.4 DETERMINING ACTUAL TRAYS-PLATE EFFICIENCY 6.4.4.5 DETERMINING FEED-POINT LOCATION 6.4.4.6 DETERMINING THE NET VAPOR VELOCITY AT FLOODING CONDITION AND THE DIAMETER OF COLUMN 6.4.4.7 6.4.4.8 DETERMINING THE HEIGHT OF THE COLUMN HEURISTICS IN DESIGNING DISTILLATION COLUMN

215 212 216 216 216 216 216 217 v

6.5

HEAT EXCHANGER, H-104 6.5.1 DESIGN BASIS 6.5.2 DESIGN PARAMETERS 6.5.3 DESIGN CRITERIA 6.5.4 DESIGN METHOD 6.5.5 DESIGN CALCULATION

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6.5.6

ASPEN CALCULATION DATA FOR HEAT EXCHANGER H-104 6.5.6.1 SUMMARY RESULTS 6.5.6.2 DETAILS INFORMATION FOR HEAT EXCHANGER 6.5.6.3 PRESSURE DROP AND VELOCITY DATA 6.5.6.4 TEMPERATURE PROFILE HEAT EXCHANGER 6.5.6.5 HEAT CURVE H-104

223 223 224 224 225 226 226 226 226 227 227 227 235 235 236 236 240 240 241 243 245 249 250 250 251 254 255

6.6

CONDENSER, H-106 6.6.1 DESIGN BASIS 6.6.2 DESIGN PARAMETERS 6.6.3 DESIGN CRITERIA 6.6.4 DESIGN METHOD 6.6.5 DESIGN CALCULATION REBOILER, H-108 6.7.1 DESIGN BASIS 6.7.2 DESIGN PARAMETERS 6.7.3 DESIGN CRITERIA 6.7.4 DESIGN METHOD SEPARATION VESSEL, T-101 6.8.1 SUMMARY OF HEURISTICS FOR PROCESS VESSELS 6.8.2 DESIGN OF SEPARATOR VESSEL T-101 STORAGE TANK 6.9.1 SHELL THICKNESS ESTIMATION 6.9.2 BOTTOM THICKNESS ESTIMATION FOR FULLY SUPPORTED FLAT BOTTOM TANK 6.9.3 DOME ROOF ESTIMATION 6.9.4 LAMINATE THICKNESS ESTIMATION BETWEEN HEAD AND SHELL 6.9.5 LIFTING LUGS DETAILS LIST OF SUPPLIER AND COSTS OF PUMPS SPECIFICATION SHEETS

6.7

6.8

6.9

6.10 6.11

CHAPTER 7: EQUIPMENT COST ESTIMATION 7.1 7.2 LIST OF EQUIPMENT 291

ESTIMATION OF PURCHASE COST AND BARE MODULE COST OF 292 EACH EQUIPMENT USING CORRELATIONS, EQUATIONS/GRAPHS AND CAPCOST vi
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7.2.1 SHELL AND TUBE HEAT EXCHANGER 7.2.2 DISTILLATION COLUMN 7.2.3 REACTOR 7.2.4 VESSEL 7.2.5 PUMP 7.3 7.4 COMMENT ON DIFFERENT COST ESTIMATION METHODS ANALYSIS OF THE EQUIPMENT COSTS ESTIMATED

291 294 298 301 302 308 USING 309

DIFFERENT METHODS 7.5 7.6 SUPPLIER AND MANUFACTURER OF THE EQUIPMENTS REQUESTS FOR QUOTATION FROM VENDOR 310 311

CHAPTER 8: PLANT COST ESTIMATION 8.1 TOTAL CAPITAL INVESTMENT ESTIMATION 316 8.1.1 METHOD 1:STUDY ESTIMATE (BASED ON OVERALL FACTOR 317 8.1.2 8.1.3 8.2 METHOD OF LANG) METHOD 2:PRELIMINARY ESTIMATE (METHOD OF GUTHRIE) METHOD 3:ORDER-OF-MAGNITUDE ESTIMATE (RATIO METHOD) 319 320 323

COST OF MANUFACTURING, COM

CHAPTER 9: PROJECT COST AND PROFITABILITY ANALYSIS 9.1 9.2 PROJECT COST OF EBMAX PLANT PROFITABILITY ANALYSIS 9.2.1 INFORMATION OF INVESTMENT CASH FLOW 9.2.2 NON DISCOUNTED CASH FLOW 9.2.2.1 NON DISCOUNTED PROFITABILITY ANALYSIS 9.2.3 THERMODYNAMIC DATA FROM ASPEN PLUS AND COMPARISON 9.2.3.1 DISCOUNTED PROFITABILITY ANALYSIS SENSITIVITY AND ERROR ANALYSIS OF THE 333 336 336 337 338 340 341

9.3

PROJECT 342

PROFITABILITY WITH VARIATION IN IMPORTANT PARAMETERS 9.4 SUMMARY OF PROFITABILITY ANALYSIS 344

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CHAPTER 10: PROCESS CONTROLLABILITY AND INSTRUMENTATION 10.1 10.2 10.3 10.4 10.5 INTRODUCTION TO CONTROL STRATEGY TYPES OF CONTROL SCHEME CONTROL SYSTEM INSTRUMENTATION PROCESS CONTROLLABILITY AND INSTRUMENTATIONS CONTROL STRATEGY OF EBMAX PLANT 10.5.1 REACTOR, R-101, R-102 10.5.2 DISTILLATION COLUMN T-102, T-103, T-104 10.5.2.1 PRESSURE CONTROL STRATEGY 10.5.2.2 LEVEL CONTROL STRATEGY 10.5.2.3 COMPOSITION CONTROL STRATEGY 10.5.3 10.5.4 10.5.5 10.6 LIGHT COLUMN (FLASH VESSEL), T-101 HEAT EXCHANGER H-101, H-102, H-103, H-104, H-105 PUMP, P-101, P-102, P-103, P-104 345 345 346 350 351 351 364 364 366 368 373 375 376 377 377 379 380 380 382 385 388 390

OVERALL PLANT CONTROL STRATEGY 10.6.1 IDENTIFICATION OF THE PROBLEM 10.6.2 SOLUTION TO CONTROL PROBLEM 10.6.3 RECOMMENDATION TO IMPROVE THE CONTROL STRATEGY EQUIPMENT DETAILS PIPING DETAILS (SIZE, LENGTH & TYPE) PIPING VALVES & FITTINGS PIPING ARRANGEMENTS WITH VALVES & FITTINGS PIPING AND INSTRUMENTATION DIAGRAM

10.7 10.8 10.9 10.10 10.11

CHAPTER 11: IMPORTANT CONSIDERATION 11.1 PLANT LAYOUT AND SITE CONSIDERATION 11.1.1 PLANT LOCATION AND JUSTIFICATION 11.1.2 PLANT LOCATION SELECTED 11.1.3 PROPOSED PLANT SITE 11.1.4 PLANT LAYOUT 11.1.4.1 PLANT LAYOUT STRATEGIES 11.1.4.2 OBJECTIVES OF PLANT LAYOUT 391 391 391 393 396 395 395 viii
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11.1.4.3 FACTORS INFLUENCING PLANT LAYOUT 11.1.4.4 EBMAX PLANT LAYOUT 11.2 PLANT WIDE CONTROL 11.2.1 PROCESS SAFETY INFORMATION IN P&IDs AND THE POTENTIAL SAFETY CONTROL PROBLEM 11.2.1.1 PROCESS SAFETY INFORMATION 11.2.1.2 POTENTIAL SAFETY CONTROL PROBLEMS 11.2.2 11.3 RELIEF SYSTEM

398 399 402 402

402 402 403 407 407 408 409 409 410 421 421 428 435

HAZARD IDENTIFICATION 11.3.0 INTRODUCTION 11.3.1 HAZARD ASSOCIATED EQUIPMENT 11.3.2 HAZARD STUDY 11.3.2.1 INTRODUCTION 11.3.3 HAZOP STUDY ON EQUIPMENTS

11.4

HAZAN 11.4.1 FAULT TREE ANALYSIS (FTA) 11.4.2 FAILURE MODES AND EFFECTS ANALYSIS (FMEA) ENVIRONMENTAL PROTECTION AND ENVIRONMENTAL IMPACT ANALYSIS (EIA) 11.5.1 11.5.2 11.5.3 ENVIRONMENTAL REQUIREMENTS WASTE DISCHARGE FROM PLANT TREATMENT OF WASTE EFFLUENT DURING NORMAL PLANT OPERATION 11.5.3.1 METHODS FOR SAFE SOLID WASTE DISPOSAL 11.5.3.2 METHODS FOR SAFE LIQUID DISPOSAL 11.5.3.3 METHODS FOR SAFE GASEOUS EMISSION

11.5

436 437 439 439 440 440 442 443 445 445 446 446 447 452 ix

11.6

WASTE MANGEMENT AND TREATMENT PLANT 11.6.1 PRE-TREATMENT 11.6.2 PRIMARY TREATMENT 11.6.3 SECONDARY WASTEWATER TREATMENT 11.6.4 ENVIRONMENT AND SURROUNDING AFFECT 11.6.5 ENVIRONMENTAL AUDITING 11.6.6 LIFE CYCLE ASSESSMENT EMERGENCY SITUATION PROCEDURES

11.7

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11.8 11.9

THE HANDLING OF CHEMICAL ACCIDENTS WITHIN THE PLANT PROCESS HAZARD CHECKLISTS 11.9.1 INTRODUCTUION 11.9.2 GENERAL QUESTION REGARDING HAZARD CHECKLIST PLANT STATY-UP AND SHUT DOWN 11.10.1 INTRODUCTION 11.10.2 PHRASES OF THE START-UP 11.10.2.1MECHANICAL COMPLETION AND INTEGRITY 11.10.2.2 PRE-COMMISSIONING AND OPEARTIONAL TESTING 11.10.2.3 START-UP AND INITIAL OPERATION 11.10.2.4 PERFORMANCE AND ACCEPTANCE TESTING 11.10.2.5 POST COMMISSIONING 11.10.3 11.10.4 PLANT START UP PROCEDURES PLANT SHUT DOWN OPERATION 11.10.4.1 TYPES OF SHUT DOWN OPERATION 11.10.4.2 PLANT SHUT DOWN PROCEDURE START-UP AND SHUT DOWN PROCEDURE FOR MAJOR UNIT GANTT CHART

454 461 461 461 465 465 465 467 467 468 468 468 469 472 473 477 480

11.10

11.10.5 11.10.6

CHAPTER 12: CONCLUSIONS AND RECOMMENDATIONS 12.1 12.2 CONCLUSION RECOMMENDATIONS 487 487

REFERENCE APPENDICES APPENDIX A: CALCULATION OF MASS BALANCE APPENDIX B: CALCULATION OF ENERGY BALANCE APPENDIX C: UTILITIES CALCULATION APPENDIX D: PURCHASED COST OF EQUIPMENT APPENDIX E: SAMPLE CALCULATION OF OPTIMUM PIPE DIAMETER APPENDIX F: DETAILED ENGINEERING DRAWING APPENDIX G: PLANT LAYOUT

488

491 512 530 532 539 540 553

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