Group Members:

Group Leader: Mohammad Al-Kashan

Barjas Al-Otaibi
Nasser Sohail
Ahmad Boland
Mutlaq Al-Shamery

Agenda
Introduction
Description of flowsheet.
Comparison between results & SRI Results.
Comparison of overall Hysys & hand calculation results.
Comparison between conversion & equilibrium reactor

results.
Overall Conclusion

Introduction
Ethylbenzene is an organic

compound with the formula

C6H5CH2CH3.
This aromatic hydrocarbon is

important in the petrochemical

industry as an intermediate in
the production of styrene.
Styrene is used for making
polystyrene, a commonly used
plastic material.

 The benzene (stream1) fed to

the tank (V-100) then

continues to the first
distillation column (C-202).
This column is called benzene

fractionator that is used to

separate benzene from other
components.

Benzene Fractionator (C-202)

Specifications of C-202 Column

specifications

Space value

Reflux ratio

Component recovery

0.97

Component recovery 2

0.99

 The outlet Liquid overhead of column (C-202) (Stream 4) is

separated to two streams; first stream will enter the shell of

first heat exchanger and exist as shell outlet.
the stream will fed to the compressor to increase the stream

pressure.
Stream 8 will enter the heater(E-104) the temperature of

feed will increase to 405 C and will combined with a large

amount of ethylene that separate from stream 2 then fed to
the first reactor (bed 1).

 The second stream will combined with a small amount of

separated ethylene from stream 2 then it will enter to the

shell of the second heat exchanger.
The stream will exist from the second heat exchanger as

(stream 7) and then will enter the Tee unit and will separate
to five streams .
These streams are used to adjust and control the reactions

inside the reactors and to decrease the temperature of the

reactors since we have exothermic reaction that produced
heat energy.

Reactor (Bed1)

Reactions involved
C6H6+ C2H4 C6H5CH2CH3
C6H6 +n C2H4 C6H5(CH2CH3)n
C6H6 +n C2H4 C6H5(CH2CH3)n

n = 10 (Heavies).

C6H5CH2CH3 + H2O C2H6 + CH4 + 2H2

C6H5CH2CH3 +2H2O C6H6 + CH4 + CO2 + 2H2

the change of conversion for each

reaction
Reactions

First
Estimation

Second
Third
Estimaation Estimation

Rxn 11

0.85

0.92

0.99

Rxn 12

0.05

0.1

0.12

Rxn 13

5E-5

1E-4

8E-4

Rxn 14

3E-3

8E-3

1.25E-2

Reactor Bed1 worksheet

 The Influents of the first reactor will enter the second

reactor (bed2) and the same reactions will be consumed

with the same value of conversion.
The set (bed2) that contains the same type of reactions will

take place in the second reactor .

The amount of ethylbenzene will increase at the outlet

stream of the second reactor (Stream B22) and the amount

of ethylene will decrease rapidly in first two reactors.

 The influents of six bed reactors will enter the tube of the

first heat exchanger (E-105).

The temperature of the influents will decrease then the feed

will enter in second heat exchanger (E-107) and exist as

stream 10.
Stream 10 will enter to the first distillation (benzene

fractionator) separation process will take in place and most

of ethylbenzene will exist from the bottom of the first
distillation to enter to second distillation.

Ethylbenzene Column
(C-203)
Stream 15 will enter the

second distilation that is called

(ethylbenzene column)
Separation process will take
place in this column and
ethylbenzene will go as
overhead product.
Ethylbenzene will exist from

the column as an overhead

and will enter to the cooler to
decrease its temperature to 66
C and exist the plant as our
main product.

Design of Ethylbenzene Column

Ethylbenzene Column Worksheet

Polyehtylbenzene column
Polyethylbenznene with other components (stream 16) and

enter the third column (poylehtylbenzene column).

In this column is used to separate polyethylbenzene as an

over head product and the other components will exist from
the bottom as residues so that we can use it as fuel.

Design of Polyethylbenzene Column

Polyethylbenzene column Worksheet

Transalkylation Reactor (R-102):

Transalkylation process is take a place in this reaction and it

used to crack the bond of polyethylbenzene to form

ethylbenzene.
The reactor is work at 400 C and 100 Psig with same

reactions and conversion used in the six bed reactors.

Design of R-102
Reactor
Heavies and water will exist

from the top of the column

and enter to couple of
coolers connected in series
then to the three-phase
seperator.
Vent gas will burn as fuels

and waste water will send

for treatment. Finally The
components that exist from
the bottom of the column
will recycle back to the C202 .

Refluxed Absorber (C-201):

Design of Refluxed Absorber

Three-Phase Seperator (V201):

Overall Mass Balance

Mass

in

= Mass

Total Benzene In:Benzene in = 108600 Ib/hr

Total Benzene Out:Wastes water Stream = 0
Vent gas Stream = 10.441 Ib/hr
Residue Stream = 0
Ethylebenzene Stream = 0.1108 Ib/hr

out

 Mass converted of benzene = [mass in (streams out )]/

mass in
= [(108589.4482)/(108600) ]* 100
= 99.99 %
Total Ethylene In:Ethylene In = 5059.6 + 33821 = 38880.6 Ib/hr
Total Ethylene Out:Vent gas = 1.7694 Ib/hr
Mass converted = [mass In (streams out )/ mass In]*100
= 99.995 %

Mass Balance Cont

Amount of Ethylbenzene:-

Mass benzene in + Mass ethylene in

= 0.9999 (108600) + 0.99995 (38880.6)
= 147467.796 Ib/hr
Amount of Ethylbenzene (Theoretical) Amount of
Ethylbenzene (Simultaneous)
= 147467.796 1.4655E5 = 917.79597 Ib/hr

Cont
Total mass out:-

Ethylbenzene = 65904 kg/hr

Residue = 178.54 kg/hr
Va = 783.41 kg/hr
Liquid = 96.450 kg/hr
Heavies = 5.9702 kg/hr
Total out = 66973.37 kg/hr

Reactors

Mass in (kg/hr)

Mass out (kg/hr)

Bed1

36503

36504

Bed2

44024

44024

Bed3

51544

51544

Bed4

59064

59064

CRV-100

66584

66584

CRV-101

66584

66584

CRv-102

14995

14995

Reactors

Temperature ( c )

Pressure ( Kpa)

Bed1

632.5

297

Bed2

353.6

283.2

Bed3

341.1

269.4

Bed4

262.8

255.6

Bed5

383.7

255.6

Bed6

383.7

255.6

CRV-102

390.8

825.3

Heat Exchangers

Type

Delta T ( c)

E-111

cooler

-4.721

E-104

heater

238

E-106

cooler

-30.22

E-103

heater

168.4

E-102

cooler

-81.06

E-101

cooler

-93.56

E-100

cooler

-372.5

E-108

heater

60.46

E-105

Shell & Tube

Tube Side = -44

Shell Side =
121.4

E-107

Shell & Tube

Tube Side = -40

Shell Side =
37.13

E-112

cooler

-190

E-113

cooler

-9.288

E-110

cooler

-81.84

SRI Results

SRI Results Cont

SRI Results Cont,

Hysys Results

Hysys Results Cont

Hysys Results Cont

Overall conclusion
- More unit has been added in this plant because:The difference between actual flow sheet and hysis to get the
control temperature and pressure to get our desired
value.

Cont
All components recovery in this plant are assumed with a

value more than 0.9 to get highest efficiency

The lower pressure of the refluxed absorber

Is more than the higher

Two Hypothetical group was added since polyethylbenzene

and heavies is not available in component library

 Multi compressors are used in series since increasing the

pressure from 100 kpa to 825.3 kpa cannot be done by one

compressor.
Same thing for valves used in series for decreasing from

very high to low pressure.

Recycled used to resolve the plant because of the difference

between hysis and SRI .

 4 sets of rxn is used to get more control on reactors process

and products.

Desired outlet stream of the plant =66162

and our outlet stream = 66477.302 kg/hr

Number of units added = 17 unit
The production of conversion reactor is more than

equilibrium

Thank You For Your Attention