DESIGN AND SIMULATION OF CUMENE PLANT USING ASPEN PLUS

A Thesis By

NIRLIPT MAHAPATRA
(Roll No. 10600018) In partial fulfillment for the award of the Degree of BACHELOR OF TECHNOLOGY IN CHEMICAL ENGINEERING

Under the esteemed guidance of

Dr. Shabina Khanam

Department ! Chemi"a# En$ineerin$

Nati na# In%tit&te ! Te"hn # $' R &r(e#a )*+*

National Institute of Te hnolog! Rour"ela

CERTIFICATE

This is to ertif! that the thesis entitled# ,De%i$n an- Sim&#ati n ! C&mene P#ant &%in$ ASPEN PL.S$ su%mitted %! Nir#ipt Mahapatra for the re&uirements for the award of 'a helor of Te hnolog! in (hemi al )ngineering at National Institute of Te hnolog! Rour"ela# is an authenti wor" arried out %! him under m! super*ision and guidan e.

To the %est of m! "nowledge# the matter em%odied in the seminar report has not %een su%mitted to an! other +ni*ersit! , Institute for the award of an! Degree or Diploma.

Dr. Shabina Khanam Asst. -rofessor Department of (hemi al )ngineering National Institute of Te hnolog! Rour"ela
ii

Date/

ACKNO0LEDGEMENT

I would li"e to ma"e m! deepest appre iation and gratitude to Dr. .ha%ina /hanam for her *alua%le guidan e# onstru ti*e riti ism and en ouragement during e*er! stage of this pro0e t. I am totall! inde%ted to her for pro*iding me the right guidan e to wor" on an emerging area of hemi al engineering. .he was *er! supporti*e through out the pro0e t and was alwa!s read! to help. I would li"e to spe iall! than" Dr. .unil /umar 1ait! who pro*ided me the opportunit! to wor" on this area. During the initial stages of the pro0e t he pro*ided me with in*alua%le guidan e and en ouragement and also helped me understand the pro0e t. 2e was alwa!s *er! inspiring and moti*ated me to wor" on this pro0e t. Than"s to Dr. R / .ingh and Dr. 2 1 3ena for %eing uniforml! e4 ellent ad*isors. The! were alwa!s *er! helpful and pro*ided %road ideas. I owe a depth of gratitude to -rof. .. /. Agarwal# 2.5.D# Department of (hemi al )ngineering# for all the fa ilities pro*ided during the ourse of m! tenure. I would li"e to than" all fa ult! and friends of (hemi al )ngineering Department# NIT Rour"ela for their support and en ouragement. .pe ial than"s to m! lass mate 1r. .h!am /umar for dis ussing the software with me and pro*iding me with ne essar! stud! material. 6astl! I would li"e to than" m! parents and sister for their onstant support# en ouragement and good wishes# without whi h this thesis wouldn7t ha*e %een possi%le.

Nir#ipt Mahapatra

iii

ABSTRACT

(umene produ tion pro ess is gaining importan e and so the pro ess needs to %e studied and %etter ideas suggested su h that the produ tion ost is redu ed. 8ith the ad*ent of omputers and simulating software li"e A.-)N -6+.9 it is possi%le to design and optimi:e a parti ular pro ess. -roper design an signifi antl! redu e produ tion ost as well as pro*ide ma"e the pro ess safe and redu e en*ironmental ha:ards. It has %een identified from pre*ious resear h papers that the ost of materials used is mu h higher than the ost of energ! needed for the pro ess. The materials# unit operations and pro esses in*ol*ed are identified. .tead! state simulation is done. )a h unit is ta"en into onsideration and the *aria%les are optimi:ed. The units are se&uentiall! optimi:ed in the order in whi h the! appear in the rough flow sheet. +se of newer e&uipments in the pro ess is suggested. The rea tor s!stem on %eing optimised %! an e&uili%rium %ased approa h ga*e the operating temperature as ;60 ( and 6<1 'en:ene< -rop!lene ratio in feed. The distillation olumns were optimised and the num%er of tra!s for %en:ene olumn was found to %e =0 %! 8 and that for umene olumn to %e =0 %! 10. The reflu4 ratio *alues were found to %e 0.> and 0.8 respe ti*el! for the olumns. The optimised temperature for flashing was identified as ?=.> (. The modified flow sheet of the optimised pro ess was prepared whi h gi*es the *alues of all the optimised *aria%les in detail.

/e!words< .imulation# 5ptimi:ation# (umene# 'en:ene# distillation# rea tor

iv

CONTENTS

PAGE NO. ABSTRACT LIST OF FIG.RES LIST OF TABLES +. INTROD.CTION 1.1 .@.T)1 (5N.ID)R)D 1.= R)6)AAN() 1.; 5'3)(TIA) 5B T2) -R53)(T ). LITERAT.RE RE3IE0 =.1 (5NA)NTI5NA6 -R5().. =.= (+RR)NT IND+.TRIA6 -R5().. =.=.1 -R5().. D).(RI-TI5N =.=.= R)A(TI5N 1)(2ANI.1 AND /IN)TI(. =.; -R5-)RTI). 5B (+1)N) =.D -R5().. D).IEN 'A.I(. 5. DESIGN/ PROCED.RE6 RES.LT AND DISC.SSION ;.1 .)F+)N() 5B (51-+TATI5N ;.= R)A(T5R D).IEN ;.=.1 R)A(TI5N. (5N.ID)RD B5R 15D)6INE ;.=.= R)A(T5R D).IEN -R5()D+R) IN A.-)N -6+. ;.=.; )F+I6I'RI+1 .T+DI). ;.=.D /IN)TI(. 'A.)D R)A(T5R 15D)6
v

i1 1ii i2 + = = ; 4 > > 6 C 11 11 +4 1> 1> 16 16 1C =1

;.=.> -R5D+(T 5+T-+T BR51 R)A(T5R ;.; -R)DI(TINE A6) (2ARA(T)RI.TI(. ;.D B6A.2 DI.TI66ATI5N TAN/ D).IEN ;.> ')NG)N) DI.TI66ATI5N (56+1N D).IEN ;.>.1 D).IEN -R5()D+R) ;.>.= R)B6+H RATI5 5-TI1IGATI5N ;.>.; B))D TRA@ 65(ATI5N 5-TI1IGATI5N ;.>.D N+1')R 5B TRA@. 5-TI1IGATI5N ;.>.> DI.TI66AT) RAT) 5-TI1IGATI5N ;.6 (+1)N) DI.TI66ATI5N (56+1N D).IEN ;.6.1 D).IEN -R5()D+R) ;.6.= R)B6+H RATI5 5-TI1IGATI5N ;.6.; B))D TRA@ 65(ATI5N 5-TI1IGATI5N ;.6.D N+1')R 5B TRA@. 5-TI1IGATI5N ;.6.> DI.TI66AT) RAT) 5-TI1IGATI5N ;.C BINA6 R).+6T. 5B 5-TI1IGATI5N 4. CONCL.SIONS REFERENCES

=1 == =D =6 =6 =6 =C =8 =? ;1 ;1 ;1 ;; ;D ;> ;6 57 4*

vi

LIST OF FIG.RES

BIE+R) N5. Big =.1 Big =.= Big =.; Big =.D Big ;.1 Big ;.= Big ;.; Big ;.D Big ;.> Big ;.6 Big ;.C Big ;.8 Big ;.? Big ;.10 Big ;.11 Big ;.1= Big ;.1; Big ;.1D Big ;.1>

TIT6) FI1a4 pro ess flow diagram (ost redu tion during pro0e t implementation Ba tors to %e onsiderd during pro ess design 5nion Diagram .e&uen e of omputation )ffe t of temperature and %en:ene,prop!lene 1ole ratio on e&uili%rium )ffe t of inert on e&uili%rium T4! for %en:ene I umene s!stem T4! for umeneIpIDI-' s!stem T4! for umeneImIDI-' s!stem Temperature of flashing *s 1ole fra tion in top and %ottom produ t of umene and %en:ene

-AE) N5. 6 11 1= 1= 1> 1? =0 =; =D =D => =6 =C =C =8 =8 =? ;= ;=

Reflu4 ratio *s 1ole fra tion of %en:ene in top produ t Beed tra! lo ation *s 1ole fra tion of %en:ene in top produ t Beed tra! lo ation *s Re%oiler heat load ('en:ene (olumn) Num%er of tra!s *s Re%oiler heat load ('en:ene (olumn) Num%er of tra!s *s 1ole fra tion of 'en:ene in top produ t Blow rate of omponents in top produ t and %ottom produ t *s distillate rate Reflu4 ratio *s 1ole fra tion of umene in top produ t Reflu4 ratio *s mol fra tion and re%oiler heat load
vii

Big ;.16 Big ;.1C Big ;.18 Big ;.1? Big ;.=0 Big ;.=1 Big ;.==

Beed tra! lo ation *s 1ole fra tion of umene in top produ t Beed tra! lo ation *s Re%oiler heat load Num%er of tra!s *s mole fra tion of umene in top produ t Num%er of tra!s *s re%oiler heat load Distillate rate *s mole fra tion of umene in top produ t Distillate rate *s mIDI-' and pIDI-' mole fra tions in top produ t

;; ;; ;D ;D ;> ;>

Blow rates and other parameters o%tained %! optimi:ation ;6

viii viiiv

LIST OF TABLES

TA'6) N5.

TIT6)

-AE) N5.

Ta%le ;.1 Ta%le ;.= Ta%le ;.; Ta%le ;.D Ta%le ;.> Ta%le ;.6 Ta%le ;.C

.tandard 2eats of Rea tion 1ole flow rate of omponents from rea tor 'oiling point of omponents Blow rates of produ ts from the flash tan" -rodu t flow rate *alues at different distillate rates Binal optimi:ed *alues of %en:ene olumn Blow rates of feed to umene olumn after s ale up

18 == =; => ;0 ;0 ;1

ix

CHAPTER 1

INTRODUCTION

+. INTROD.CTION +.+ SYSTEM CONSIDERED The s!stem onsidered for stud!# simulation and optimi:ation is a umene produ tion plant. The pro ess des ri%ed %! -eterson and . hmidt (=00=) is ta"en as %ase for simulating the s!stem. The pro ess des ription of Turton et al. (=00;) pro*ides rele*ant and *alua%le data re&uired for the simulation of the pro ess. Raw materials fed to the plant are %en:ene and prop!lene (ma! ontain propane as an impurit!) in whi h %en:ene is in e4 ess. Aarious unit operations and pro esses are re&uired to %e ta"en are of whi h are des ri%ed in some detail %elow. The ma0or units in the pro ess plant are the rea tor se tion and the separator se tion. +.) RELE3ANCE Isoprop!l %en:ene popularl! "nown as umene is the prin ipal hemi al used in the

produ tion of phenol and its oIprodu t a etone on an industrial s ale. It is also the starting material in the produ tion of a etophenone# meth!l st!rene# diisoprop!l %en:ene and di um!l pero4ide. 1inor uses of umene in lude as a thinner for paints# enamels# and la &uersJ as a onstituent of some petroleumI%ased sol*ents# su h as naphthaJ in gasoline %lending diesel fuel# and highIo tane a*iation fuel. It is also a good sol*ent for fats and resins and has %een suggested as a repla ement for %en:ene in man! of its industrial appli ations. Around ?8K of umene is used to produ e phenol and its oIprodu t a etone. 2owe*er# the re&uirement of umene is largel! dependent on the use of phenol7s deri*ati*es whi h ha*e resulted in in reasing re&uirement rates for umene. The largest phenol deri*ati*e is %isphenolIA ('-A) whi h supplies the pol! ar%onate (-() se tor. -( resins are onsumed in automoti*e appli ations in pla e of traditional materials su h as glass and metals. Ela:ing and sheet uses# su h as ar hite tural# se urit! and gla:ing outlets# are also important -( appli ations. The third largest use for -( is opti al media su h as ompa t dis s ((Ds) and digital *ersatile dis s (DADs). Another phenol deri*ati*e is growth. L. hmidt# =00>M aprola tam whi h is used mainl! to ma"e n!lon 6. It is mainl! the resin se tor of the n!lon mar"et that is seeing

(umene is produ ed %! the al"!lation of %en:ene with prop!lene o*er an a id atal!st li"e aluminium hloride# %oron trifluoride# phosphori a id# h!drogen fluoride# supported phosphori a id (.-A) et . The usage of the a%o*e atal!sts poses a lot of pro%lems li"e produ t &ualit!# lower atal!st a ti*it!# en*ironmental ha:ard# atal!st nonIregenera%ilit! et and has %een repla ed %! :eolites in most of the pro esses. In the present wor" the umene produ tion plant is simulated using A.-)N -6+. 9 and the si:es# the temperature and other rele*ant parameters are o%tained %! optimi:ation. 1AT6A'9# 1. )4 el and 5rigin -ro 8.0 are used to plot graphs in the following simulation from whi h an optimum *alue is estimated. The optimi:ed *alues o%tained an pro*ide a lot of insight %efore a tual plant ommissioning is done. +.5 OB8ECTI3E OF THE PRO8ECT (onsidering the importan e of the present pro ess# wor" was underta"en to design and simulate the umene produ tion pro ess using A.-)N -6+. 9 software. The o%0e ti*es of the present pro0e t are following. To design a :eolite atal!st %ased umene produ tion pro ess and stud! the sensiti*it! anal!sis. To optimi:e the ontents of the flow sheet for minimi:ation of loss of material along with a greater produ tion of umene and low re&uirement of energ!.

CHAPTER 2

LITERATURE REVIEW
4

). LITERAT.RE RE3IE0 ).+ CON3ENTIONAL PROCESS (umene is produ ed %! the al"!lation of %en:ene with prop!lene o*er an a id atal!st. (atal!sts li"e aluminium hloride# %oron trifluoride# h!drogen fluoride and solid phosphori a id (.-A) are normall! used. 5*er the !ears these atal!sts ha*e gi*en wa! to :eolite %ased atal!sts. There are some inherent pro%lems asso iated with the on*entional a id atal!sts. Disad*antages of using solid phosphori a id (.-A) -ro ess 1. 6ower a ti*it! =. (atal!st nonIregenera%ilit! ;. +nloading of spent atal!st from rea tor diffi ult D. Relati*e high sele ti*it! to he4!l %en:ene >. .ignifi ant !ield of DI-' Disad*antages of using Aluminium hloride as atal!st 1. 2igh orrosion =. )n*ironmental ha:ard ;. 8ashing step for atal!st remo*al. ).) C.RRENT IND.STRIAL PROCESS (umene is an important hemi al in the present industrial world and its uses are steadil! in reasing. The pro ess followed for the produ tion of umene is the atal!ti al"!lation of %en:ene with prop!lene and now a da!s :eolite %ased atal!sts are used in pla e of the normal a id %ased atal!sts due to added ad*antages. (umene produ tion pro ess has %een greatl! studied and the rea tion me hanism and the rea tion "ineti s ha*e %een spe ified %! man! resear hers. 'oth e4perimental as well as omputer %ased simulation and optimi:ation studies ha*e %een arried out %! *arious resear hers. The signifi ant wor"s of *arious resear hers whi h ha*e %een helpful in m! pro0e t are des ri%ed in %rief %elow.

The FI1a4 N pro ess on*erts a mi4ture of %en:ene and prop!lene to high &ualit! umene using a regenera%le :eolite atal!st. The FI1a4 N pro ess is hara teri:ed %! a e4 eptionall! high !ield# %etter produ t &ualit!# less solid waste# de rease in in*estment and operating osts and a orrosion free en*ironment. The FI1a4 N pro ess de*eloped %! +5uses FGI=000, FGI=001 atal!st whi h is a *ariant of O I :eolite. L. hmidt# =00>M

Big. =.1 FI1a4 pro ess flow diagram L. hmidt# =00>M ).).+ PROCESS DESCRIPTION The FI1AHN pro ess pro*ides a *er! good umene !ield and &ualit!. The FGI=000 :eolite %ased atal!st used in the FI1AHN pro ess operates with a low flow rate of %en:ene and hen e in*estment and utilit! osts are redu ed greatl!. FGI=000 is nonI orrosi*e and regenera%le# a*oiding the signifi ant maintenan e and atal!st disposal pro%lems asso iated with .-A and Al(l; s!stems. (ompared to other :eolite %ased umene te hnologies# the FI 1AHN pro ess pro*ides the highest produ t &ualit! and great sta%ilit!. Impurities in the feed ha*e less effe t.
6

The FI1AHN pro ess flow s heme is shown in fig =.1 a%o*e. The al"!lation rea tor is di*ided into four atal!ti %eds present in a single rea tor shell. The fresh %en:ene feed is passed through the upperImid se tion of the depropani:er olumn to remo*e e4 ess water and then sent to the al"!lation rea tor. The re ! le %en:ene to the al"!lation and transal"!lation rea tors is drawn from the %en:ene olumn. This mi4ture of fresh and re ! le %en:ene is harged through the al"!lation rea tor. The fresh prop!lene feed is split %etween the atal!st %eds and is full! onsumed in ea h %ed. An e4 ess of %en:ene helps in a*oiding pol! al"!lation and minimi:ing olefin oligomeri:ation. 'e ause the rea tion is e4othermi in nature# the temperature rise in the al"!lation rea tor is ontrolled %! re ! ling a portion of the rea tor effluent to the rea tor inlet to a t as a heat sin". The inlet temperature of ea h downstream %ed is further redu ed to the same temperature as the first %ed inlet %! in0e ting a portion of ooled rea tor effluent %etween the %eds. )ffluent from the al"!lation rea tor flows to the depropani:er olumn whi h remo*es the propane the e4 ess water. The %ottoms stream of the depropani:er olumn goes to the %en:ene olumn where e4 ess %en:ene is olle ted o*erhead and re ! led. The %en:ene olumn %ottoms stream goes to the umene olumn where umene is re o*ered o*erhead. The umene olumn %ottoms stream# predominantl! diisoprop!l%en:ene (DI-')# goes to the DI-' olumn. If the prop!lene feed ontains e4 essi*e %ut!lenes# or if the %en:ene feed ontains e4 essi*e toluene# %ut!l%en:enes and,or umene are distilled out and purged from the o*erhead se tion of the DI-' olumn. The DI-' stream lea*es the olumn %! wa! of the side draw and is re ! led %a " to the transal"!lation rea tor. The DI-' olumn %ottoms onsist of hea*! aromati %!Iprodu ts# whi h are normall! %lended into fuel oil. .team or hot oil pro*ides the heat for the produ t fra tionation se tion. The re ! le DI-' from the o*erhead of the DI-' olumn om%ines with a portion of the re ! le %en:ene and is harged downflow through the transal"!lation rea tor. In the transal"!lation rea tor# DI-' and %en:ene are on*erted to more umene. The effluent from the transal"!lation rea tor is then sent to the %en:ene olumn. The new FGI =001 atal!st is utili:ed in the al"!lation rea tor while the original FGI=000 atal!st remains in the transal"!lation rea tor. )4pe ted atal!st ! le length is =PD !ears# and the atal!st should last for at least three ! les with proper are. At the end of ea h ! le# the atal!st is t!pi all! regenerated e4 situ *ia a simple ar%on %urn %! a ertified regeneration ontra tor. 2owe*er# the unit an also %e designed for in situ regeneration. The FI1a4N pro ess t!pi all! produ es near e&uili%rium le*els of umene (%etween 8> and ?> mol K) and DI-' (%etween > and 1> mol K). The DI-' is separated from the umene and is rea ted with
7

re ! le %en:ene at optimal onditions for transal"!lation to produ e additional umene. L. hmidt# =00>M# L-eterson and . hmidt# =00=M ).).) REACTION MECHANISM AND KINETICS The following rea tion me hanisms are proposed for the al"!lation of %en:ene to umene pro ess. The ma0or rea tions ta"ing pla e are alkylation and trans-alkylation. The other rea tions in*ol*ed in lude isomerisation and dis-proportionation. The rea tion me hanism as well as the rea tion "ineti s ma! *ar! depending on the atal!st used. The rea tion an pro eed %! with or without ar%onium ion intermediate. LDing and Bu# =00>M The rates of rea tion data was o%tained for different atal!sts from the wor" done %! *arious resear hers. The "ineti data and the rea tion onditions spe ified %! Turton et al (=00;) for a parti ular atal!st ha*e %een used in the present wor". The rea tion "ineti data is shown %elow -rop!lene Q %en:ene umene / R =.8 S 10 RateR"
C

) ("3,"mol) 10D1CD
p %

-rop!lene Q umene pIdiisopro!l %en:ene / R =.;= S 10 RateR"

?

) ("3,"mol) 1D6CD=
p I1 I;

(The unit for rates is "mol s m ) LTurton et al# =00;M TransIal"!lation rea tion /R 6.>= S 10 e4p (=C=D0,RT) The e&uili%rium data for transIal"!lation rea tion is o%tained for modified :eolite %eta atal!st# @.'2I01. L6ei et al# =00CM
8
I;

Brom *arious wor"s on umene produ tion me hanism the o*erall rea tion an %e assumed to onsist of the following stages. A#('#ati n

I% meri%ati n

Tran%a#('#ati n

Di%9pr p rti nati n

10

).5 PROPERTIES OF C.MENE Description< (olorless li&uid with a sharp# penetrating aromati or gasIli"e odour L'uda*ari# 1?8?J (a*ender# 1??DM Boiling Point< 1>=.DT( L6ide# 1??>M Melting Point< I?6.0T( L6ide# 1??>M Density< 0.8618 g, m at =0T( L6ide# 1??>M Refractive Index< 1.D?1> at =0T( L. hul: et al.# 1??;MJ 1.D8? at =>T( L6ewis# 1??;M Solu ility< Insolu%le in waterJ mis i%le in a etone# %en:ene# and ethanol L6ide# 1??>M
!lash Point< ;?T(# losed up L'uda*ari# 1?8?M
;

Reactivity< (om%usti%le L6ewis# 1??;M# not ompati%le with o4idi:ers# nitri a id and sulphuri a id.

).4 PROCESS DESIGN BASICS -ro ess design is a *er! important aspe t %efore an! pro0e t implementation as a proper design during the initial stages an sa*e osts to a great e4tent. The ost in*ol*ed in designing a pro0e t is *er! less ompared to the onstru tion ost and it an %e greatl! helpful in ma4imi:ing profits of the plant as well as pro*iding a safe en*ironment. The plot shown in Big. =.= gi*es a %rief idea of how proper plant design an ut osts to a great e4tent.

Big =.= (ost redu tion during pro0e t implementation LDimian# =00;M The following points need to %e ta"en are for a proper pro ess design.
11

1. Ra" material cost reduction. .ele ti*it! of rea tion is in reased %! proper use of atal!sts. In reasing sele ti*it! an redu e separation and re ! le osts. =. #apital-cost reduction. 'etter flow sheeting an redu e apital osts effe ti*el! ;. $nergy use reduction. -in h point anal!sis is used for energ! sa*ing. D. Increased process flexi ility. -ro ess plant should %e a%le to handle a range of feed ompositions. >. Increased process safety. Nonlinear anal!sis an %e done to ma"e the pro ess safer. 6. Increased attention to %uality& Redu tion of %! produ ts and the effe ti*e use of pro ess ontrol e&uipment an lead to pro ess safet!. C. Better environmental performance& 1inimi:ation of harmful wastes to the en*ironment.

Big =.; Ba tors to %e onsiderd during pro ess design LDimian# =00;M The order in whi h designing should %e done follows a s!stemati pro edure as shown in Big =.D.

Big =.D 5nion Diagram (traditional pro ess design hierar h! of phases) L6innhoff# 1??DM
12

A pro ess simulation diagram is drawn from the pro ess flow diagram. The

hemi al

omponents are spe ified. The hemi al omponent properties are generall! a*aila%le in a standard data %ase. The input streams are spe ified. Thermod!nami modelling is done. .eries of simulations are run for on*ergen e of a parti ular *aria%le. .ensiti*it! anal!sis whi h onsists of *ar!ing the sampled *aria%les as a fun tion of the manipulated *aria%les is normall! done. The ma0or parts of a umene produ tion plant are rea tor s!stem# separation s!stem and the! are optimi:ed.

13

CHAPTER 3

DESIGN:

PROCEDURE,

RESULT & DISCUSSION

14

5. DESIGN/ PROCED.RE6 RES.LT AND DISC.SSION 5.+. SE:.ENCE OF COMP.TATION This hapter is di*ided into two main parts as (i) Rea tor and (ii) .eparator. The rea tor design in*ol*es design of e&uili%rium %ased rea tor as well as "ineti %ased rea tor. The separator s!stem in*ol*es the design of flash tan" and distillation olumn. As the produ t purit! is in reased %! in reasing the wor"ing ost of the rea tor# the separation ost de reases and *i e *ersa. The se&uen e of omputation followed is shown in Big. ;.1.

Big ;.1 .e&uen e of omputation 5.) REACTOR DESIGN Rea tor is the heart of a hemi al pro ess plant. Design of a rea tor re&uires data from thermod!nami s# hemi al "ineti s# fluid me hani s# heat transfer# mass transfer and e onomi s. A properl! designed rea tor an minimi:e the produ tion of unwanted produ ts and hen e redu e the purifi ation osts. The alkylation and trans-alkylation rea tors are the main rea tors in a umene produ tion plant and the! need to %e designed for optimum use of material and energ!. In all the optimi:ation wor" done Douglas Doctrine (the osts of raw materials and produ ts are usuall! mu h larger than the osts of energ! or apital in a t!pi al hemi al pro ess. Therefore the pro ess must %e designed (in*esting apital and pa!ing for energ!) so as to not waste feed sto "s or lose produ ts (parti ularl! in the form of undesira%le produ ts) is
15

followed. L6u!%en# =010M /ineti

model

an %e

onsidered if a urate "ineti

data is

a*aila%le. 'ut a plant in*ol*es industrial rea tors that are *er! omple4 and hen e a proper om%ination of stoi hiometri and "ineti rea tor needs to %e used. /ineti model an determine the produ tion rate where as stoi hiometri model an des ri%e the formation of %! produ ts and impurities ne essar! for the design of separators. )&uil%rium %ased rea tors li"e REI''. in A.-)N -6+.9 an gi*e a realisti idea a%out the ma4imum a hie*a%le performan e. The! wor" a uratel! for fast rea tions. The REI''. rea tor predi ts the e&uili%rium on entration %! Ei%%s free energ! minimi:ation. LDimian# =00;M Eenerall! in rea tor design an e&uili%rium model is prepared and then the "ineti model. The following rea tion me hanism was proposed %! *arious resear hers for al"!lation of %en:ene %! umene. 5.).+ REACTIONS CONSIDERED FOR MODELING A#('#ati n prop!lene Q %en:ene umene prop!lene Q umene pIdiisopro!l %en:ene I% meri%ati n pIdiisoprop!l %en:ene mIdiisoprop!l %en:ene Tran%9a#('#ati n pIdiisoprop!l %en:ene Q %en:ene = umene mIdiisoprop!l %en:ene Q %en:ene = umene Di%pr p rtinati n = umene pIdiisoprop!l %en:ene Q %en:ene = umene mIdiisoprop!l %en:ene Q %en:ene 5.).) REACTOR DESIGN PROCED.RE IN ASPEN PL.S The feed is a mi4ture of %en:ene and prop!lene su h that %en:ene is in e4 ess. In general prop!lene is not a*aila%le in the pure form and has some amount of propane as inert. The separation ost of propane is high and hen e normall! propane is not remo*ed from the prop!lene feed into the rea tor. A high on*ersion of prop!lene is desired and the unrea ted
16

(1) (=) (;) (D) (>) (6) (C)

prop!lene an %e flashed off along with the inert propane. REI''. rea tor wor"s %! Ei%%s free energ! minimi:ation. Al"!lation and transIal"!lation rea tors need not %e modelled separatel! as the! an %e om%ined into one e&uili%rium rea tor. The rea tant# produ ts as well as the intermediates as seen from the rea tion me hanisms are spe ified into the omponent list. .@.5-0 or Ideal propert! ta%le is used. A temperature range of ;00 to D00 degree (elsius is spe ified and a proper temperature hosen. -ressure of => atm is hosen from pre*ious industrial resear h wor". L6u!%en# =010M 5.).5 E:.ILIBRI.M ST.DIES The e&uili%rium is affe ted %! the temperature as well as the %en:ene,prop!lene mole ratio. The al"!lation and transal"!lation rea tion is usuall! arried out at atmospheri pressure. Therefore# the effe t of pressure on the e&uili%rium was not onsidered in the present stud!. .e*en rea tor models are a*aila%le in A.-)N -6+.. The e&uili%rium %ased REI''. rea tor is used to find the produ t omposition at whi h the Ei%%s free energ! of the produ t is minimum. The restri ted hemi al e&uili%rium approa h is used and the rea tions mentioned a%o*e are spe ified. The temperature approa h for an indi*idual rea tion is used. The feed stream mole flow is set as 1 "mol , hr and the feed stream onsists of %en:ene# prop!lene and propane (inert mi4ed with the prop!lene stream). Amount of inert in feed is "ept fi4ed. The rea tor temperature is set to ;>0 ( and the rea tor pressure is set to => atm. (a) The sele ti*it! of umene and on*ersion of prop!lene (limiting reagent) is studied %! *ar!ing the %en:ene,prop!lene mole ratio in the feed "eeping the amount of inert fi4ed. The effe t of temperature *ariation (;00PD00 () on the sele ti*it! and the on*ersion is also studied. (%) Again# the *ariation in the sele ti*it! of mIDI-' and pIDI-' with temperature and %en:ene,prop!lene mole ratio in the feed is studied. The on*ersion and sele ti*it! were al ulated using e&uations 8 to 11. K.ele ti*it! of umene R B ,(Bprop!lenefeedIBprop!leneprod)100K (8)
0 0

umeneprodu t

K(on*ersion of prop!lene R (Bprop!lenefeedIBprop!leneprod),Bprop!lenefeed 100 K K.ele ti*it! of mIDI-' R Bmdip%produ t,(Bprop!lenefeedIBprop!leneprod) 100K
17

(?)

(10)

K.ele ti*it! of pIDI-' R Bpdip%produ t,(Bprop!lenefeedIBprop!leneprod) 100K 8here B umeneprodu t R molar flow rate of umene in produ t Bprop!lenefeed R molar flow rate of prop!lene in feed Bprop!leneprod R molar flow rate of prop!lene in produ t Bmdip%produ t R molar flow rate of mIDI-' in produ t Bpdip%produ t R molar flow rate of pIDI-' in produ t

(11)

R.T5I( rea tor model was used to find the standard heat of rea tion for different rea tions 1 to 6 mentioned a%o*e. The standard heats of rea tion ha*e %een ta%ulated in Ta%le ;.1. The heat of rea tion for isomerisation was found to %e :ero as e4pe ted. The all other rea tions were found to %e e4othermi e4 ept transIal"!lation rea tions as o%ser*ed from the ta%le.

Ta%le ;.1 .tandard 2eats of Rea tion Rea tion Num%er .tandard 2eat of Rea tion (/ al,/g mol) 1 = ; D > 6 C I=;.6C0 I=D.;=1 0 0.6D? 0.6D? I0.;=> I0.;=D

E!!e"t ! temperat&re an- ben;ene<pr p'#ene m #e rati . The effe t of temperature and %en:ene,prop!lene mole ratio on e&uili%rium on*ersion of prop!lene and sele ti*it! of produ ts# umene# mIDI-'# and pIDI-' is shown in Big. ;.=. The on*ersion of prop!lene was found to in rease with in rease in %en:ene,prop!lene mole ratio for a fi4ed temperature as o%ser*ed from the Big. ;.=(a). This is %e ause of redu ed proportion of prop!lene in feed. 2owe*er# *ariation of on*ersion of prop!lene was found to %e negligi%l! small a%o*e the %en:ene,prop!lene mole ratio in feed of ;. The on*ersion of prop!lene was found to de rease with in rease in temperature for a fi4ed %en:ene,prop!lene
18

mole ratio as o%ser*ed from the Big. ;.=(a). This is %e ause of the fa t that o*erall heat of rea tions is e4othermi as shown in Ta%le ;.1. The sele ti*it! of umene was found to in rease with in rease in %en:ene,prop!lene mole ratio at a fi4ed temperature as the pol!al"!lation rea tions are redu ed %e ause of e4 ess amount of %en:ene present in the feed (Big. ;.=(%)). Again# with in rease in temperature# the sele ti*it! of umene in reases for a fi4ed %en:ene,prop!lene mole ratio as transal"!lation rea tions (endothermi # Ta%le ;.1) are dominant at high temperature.

=a>

=b>

="> Big ;.= )ffe t of temperature and %en:ene,prop!lene mole ratio on e&uili%rium (a) on*ersion of prop!lene# (%) sele ti*it! of umene# and ( ) sele ti*it! of mIDI-' and pI DI-'.

=a>

=b> Big. ;.; )ffe t of inert on e&uili%rium (a) on*ersion of prop!lene (%) sele ti*it! of umene

The distri%ution of mIDI-' and pIDI-' is shown in Big. ;.= ( ). Brom the figure it was o%ser*ed that sele ti*it! of mIDI-' is signifi antl! higher than pIDI-'. This is %e ause of the fa t that mIDI-' is thermall! more sta%le ompared to pIDI-'. Therefore# pIDI-' formed in al"!lation rea tion isomerises to more sta%le meta isomer. E!!e"t ! inert n e?&i#ibri&m. The prop!lene stream used in al"!lation pro ess is usuall! o%tained %! p!rol!sis of petroleum fra tions that ontains small amount of propane as impurit!. -ropane need not %e remo*ed from the prop!lene stream as it a ts as an inert and does not ta"e part in the rea tion. -resen e of inert has *er! slight effe t on the on*ersion as well as sele ti*it! as shown in Big.;.;. The on*ersion of prop!lene de reases slightl! with higher *olume per ent of inert in feed and in reases slightl! with the same. 5.).4 KINETICS BASED REACTOR MODEL /ineti s %ased rate data was o%tained from the wor" of *arious resear hes and is mentioned a%o*e. A R-6+E model is used in A.-)N -6+. to model the rea tor. The design model spe ified in the %oo" %! Turton et al (=00;) is used. The rea tions o ur in the *apour phase in the presen e of a solid atal!st (assumed to ha*e 0.> *oid fra tion and a =000 "g,m; solid densit!). The rea tor is run at high pressure (=> %ar) sin e the moles of rea tants are more than the moles of produ t (6e (hatelier7s prin iple). A temperature of ;60 degree ( and a %en:ene,-rop!lene mole ratio of 6 is used. A flow rate of ;;0 "mol,hr is used for the simulation. The "ineti model generated few errors su h as R-6+E e4ited %e ause integration failed. inde4 R (I1) pro%a%le ause is in orre t "ineti s. he " rateI onstant parameters and molar *olume al ulations. 5.).@ PROD.CT O.TP.T FROM REACTOR Assuming the REI''. model for the initial al ulations for distillation olumns an gi*e a good idea a%out the distillation pro ess in a umene plant. REI''. model with an input feed rate of 100 "mol,hr and %en:ene< prop!lene feed ratio of 6<1 with an inert on entration of >K in prop!lene stream# temp. of ;60 degree ( and a pressure of => %ar is used. The flow

rates o%tained at the produ t side are noted.The non ondensa%le omponents in the produ t side i.e. prop!lene and propane are remo*ed in flash tan". These omponents ha*e fuel *alue onl! as the! annot %e ompletel! purified. .o the rea tion onditions should %e so ad0usted that the prop!lene in feed is totall! on*erted to the produ t. The on entration of nonI ondensa%le omponents from rea tor is gi*en in Ta%le ;.=. This data is used for further designing. Ta%le ;.= 1ole flow rate of omponents from rea tor (omponent 'en:ene (umene mIDI-' pIDI-' T5TA6 1ole Blow "mol,hr C=.8> 10.;1 1.CC 0.DC 8>.D

5.5 PREDICTING 3LE CHARACTERISTICS Rea tors and separators an %e onsidered as the %a " %one of an! hemi al pro ess plant. The ost optimi:ation of an! plant depends largel! on the rea tors and the distillation olumns. The %asis of distillation is phase e&uili%rium that ma! %e A6) (Aapour li&uid e&uili%rium) and 66) (6i&uid li&uid e&uili%rium). 'efore designing an! distillation e&uipment the A6) hara teristi s need to %e studied as the! gi*e a fair amount of idea a%out the ease of distillation. The T4! diagram or temperature *ersus li&uid omposition (4) and *apour omposition (!) are plotted. A fat ur*e generall! shows that the li&uids in a mi4ture an %e easil! separated. The %oiling point data of the three ma0or omponents in the distillation olumn is shown in Ta%le ;.; %elow.

Ta%le ;.; 'oiling point of omponents (omponent 'en:ene (umene DI-' 'oiling point in degree (elsius 80.= 1>=.D =0?.8

The produ t stream from a ondenser tan" is sent to a distillation olumn. RADBRA( model is used. In the industrial pro ess three distillation olumns are used i.e %en:ene olumn# followed %! umene olumn and DI-' olumn.The RADBRA( model is a rigorous model for *arious multistage li&uid *apour fra tionation operations and hen e is used for the simulation 'efore going in for the design of the distillation olumn the A6) diagrams need to %e onsidered. The industrial pro esses urrentl! followed show that in the 1 %en:ene and umene need to %e primaril! separated and in the =
nd st

olumn

olumn umene and DI-'

need to %e separated. The NRT6 (non random two li&uid) ph!si al propert! pa "age is used used to plot the *apour li&uid e&uili%rium TIH@ for 'en:eneI umene and (umeneIDI-' s!stems. The A6) plots are shown in Big ;.D to ;.6 for different s!stems.

Big ;.D T4! for %en:ene I umene s!stem

Big ;.> T4! for umeneIpIDI-' s!stem

Big ;.6 T4! for umeneImIDI-' s!stem It an %e inferred from plots Big. ;.D to ;.6 that separation would %e eas! and a distillation olumn with fewer tra!s and a smaller reflu4 ratio an %e used. A:eotrope is not formed. Blash distillation should %e tried as separation is easier. 5.4 FLASH DISTILLATION TANK DESIGN Distillation is tried using flash tan" as the ost of operation is *er! low. B6A.2= model is sele ted. .@.5-0 propert! method is sele ted# whi h wor"s %! ideal or Roult7s law. -ressure of the flash tan" is set as 1 %ar. The input flow rate is same as mentioned in Ta%le ;.=. The minimum %oiling point in the mi4ture is that of %en:ene at 80.= degree ( at 1 atm and hen e

a temperature of 8> to ?C.> is onsidered for flashing. The mole fra tions of %en:ene and umene in the %ottom and top produ ts are found out at *arious flashing temperatures and plotted in Big. ;.C.

Big ;.C Temperature of flashing *s 1ole fra tion in top and %ottom produ t of umene and %en:ene Assuming a produ t purit! of ?>K %en:ene in the top produ t the flashing temperature is identified to %e ?=.> degree (. The flow rates of produ ts from the flash tan" are shown in Ta%le ;.D. Ta%le ;.D Blow rates of produ ts from the flash tan" ?=.> degree ( '5TT51 -rodu t T5- produ t 'en:ene 18.?>186> >.;?)Q01 (umene C.8?;8D?6; =.D161>0;1 mIDI-' 1.68DC;8;= 0.08>=616C pIDI-' 0.D>=8C??; 0.01C1=006

The flow rates of Ta%le ;.D a t as a feed to the %en:ene olumn.

25

5.@ BENAENE DISTILLATION COL.MN DESIGN 5.@.+ DESIGN PROCED.RE RADBRA(I1 is sele ted for designing the 'en:ene distillation olumn. .@.5-0 propert! method is sele ted and the flow rates from Ta%le ;.D are used. The pressure is "ept fi4ed at 1.C> %ar and the temperature is "ept fi4ed at ?0 degree (elsius. These two *aria%les are o%tained from the e4perimental data spe ified %! Turton et al (=00;). These temperature and pressure data ha*e %een used in the wor" %! 6u!%en (=010). The *aria%les that an %e optimi:ed are reflux ratio' num er of feed trays' feed tray location and distillate rate . In the initial assumption the distillate rate is "ept at half the *alue of the feed rate. A total ondenser is used in the pro ess and an e&uili%rium %ased approa h is used. 5.@.) REFL.B RATIO OPTIMIAATION The num%er of tra!s (in luding %oiler and ondenser as a tra!) is "ept fi4ed at an! *alue sa! 1>. The feed tra! is *aried "eeping the num%er of tra!s fi4ed. Now for ea h different ratio of num%er of tra!s to feed tra! a series of reflu4 ratio starting from 0.1 is onsidered. The pro ess is run and the mole fra tion of %en:ene in the top produ t as well as the re%oiler heat load data are used and a graph is plotted as shown in Big ;.8. Reflu4 ratio is optimi:ed %! the *aria%le mole fra tion of %en:ene in the top produ t.

Big ;.8 Reflu4 ratio *s 1ole fra tion of %en:ene in top produ t
26

An optimum reflux ratio value of a out (&) is identified from Big ;.8. At higher *alues of feed tra! lo ation ( lose to re%oiler) lesser reflu4 ratio is re&uired. Note that ondenser is onsidered as the first stage and the re%olier as the last. 5.@.5 FEED TRAY LOCATION OPTIMIAATION The reflu4 ratio is "ept fi4ed at 0.> and the num%er of tra!s is "ept fi4ed at 1>. The position of the feed tra! is *aried and its affe t on the re%oiler heat load and the mole fra tion of %en:ene in the top produ t is studied %! plotting graphs in Big.;.? and ;.10.

Big ;.? Beed tra! lo ation *s 1ole fra tion of %en:ene in top produ t

Big ;.10 Beed tra! lo ation *s Re%oiler heat load ('en:ene (olumn)
27

Brom Big. ;.? and ;.10 it an %e identified that after a ertain optimum *alue of feed tra! lo ation is a hie*ed there is hardl! an! hange in the re%oiler heat load and the on entration of %en:ene in the top produ t. Ratio of *) y + is identified as the optimum ratio. 5.@.4 N.MBER OF TRAYS OPTIMIAATION The ratio o%tained a%o*e is "ept onstant and the num%er of tra!s is *aried.

Big ;.11 Num%er of tra!s *s Re%oiler heat load ('en:ene (olumn)

Big ;.1= Num%er of tra!s *s 1ole fra tion of 'en:ene in top produ t
28

It an %e identified from Big. ;.11 and ;.1= that the produ t &ualit! (mole fra tion of %en:ene in top produ t) and the re%oiler heat load donot *ar! signifi antl! after an optimum num%er of tra!s is rea hed. ,he optimum num er of trays is o tained as -(& 5.@.@ DISTILLATE RATE OPTIMIAATION Distillate rate needs optimi:ation as higher distillate rates an in rease the &ualit! and flow rate of top produ t %ut the re%oiler heat load also signifi antl! in reases. /eeping distillate rates *er! high an impro*e the &ualit! of top produ t %ut upto a ertain limit. Aer! high distillate rates pre*ent proper separation. The mole fra tions of umene and %en:ene in the top and %ottom produ ts are plotted in Big. ;.1;.

Big. ;.1; Blow rate of omponents in top produ t and %ottom produ t *s distillate rate (flow rates in "mol,hr)
29

Ta%le ;.> -rodu t flow rate *alues at different distillate rates 'en:ene flow rate Distillate flow rate "mol,hr 10 1D.D?1666D 16 18 =0 == top produ t "mol,hr ?.???=?>C6 1D.D?0C1 1>.??8?608 1C.??88608 18.?>186D? 1.?0)Q01 (umene flow rate top produ t "mol,hr 'en:ene flow rate %ottom produ t "mol,hr (umene flow rate %ottom produ t "mol,hr

0.000C0D=D 8.?>=>6?=D C.8?;1D> 0.000?>6;? D.D611>D?6 C.8?=8?; 0.0010;?== =.?>=?0D=; C.8?=81 0.0011;?=D 0.?>;00D=C C.8?=C1 1.0D81=8D= 8.D1)I08 ;.0D806>D8 1.66)I08 6.8D>C=1 D.8D>C8D

The &ualit! of top produ t hanges signifi antl! in the 18 P =0 "mol,hr distillate flow rate region. The produ t &ualit! initiall! in reases as an %e seen from Big. ;.1; %ut after a ertain *alue of distillate rate it doesn7t rise. The Ta%le ;.> gi*es an idea a%out the flow rates of *arious omponents in top and %ottom produ ts on *ariation of distillate rate. The final optimi:ed *alues for the %en:ene olumn are shown in Ta%le ;.6. Ta%le ;.6 Binal optimi:ed *alues of %en:ene olumn Num%er of Tra!s Beed Tra! 6o ation Reflu4 Ratio Distillate Rate TemperatureU -ressureU U 6iterature Data =0 8 0.> 1? "mol,hr ?0 degree ( 1.C> %ar

30

5.C C.MENE DISTILLATION COL.MN DESIGN 5.C.+ DESIGN PROCED.RE RADBRA(I1 is sele ted for designing the umene distillation olumn. .@.5-0 is sele ted and the %ottom produ t flow rate *alues from the %en:ene olumn are the feed flow rate *alues to the umene olumn. The pressure is "ept fi4ed at 1 %ar and the temperature is "ept fi4ed at 16D degree (elsius. 2igher temperature data ga*e iteration errors and hen e all wor" is arried out at this temperature. The pressure data has %een used in urrent resear h papers L6u!%en# =010M. Now in the umene distillation olumn the *aria%les that an %e optimi:ed are reflu4 ratio# num%er of feed tra!s# feed tra! lo ation and distillate rate. In the initial assumption the distillate rate is "ept at half the *alue of the feed rate. A total ondenser is used in the pro ess and an e&uili%rium %ased approa h is used. The %ottom produ ts from the umene olumn are s aled up %! a fa tor of 10 %efore optimi:ation is started. The s aled up *alues are represented in Ta%le ;.C %elow. Ta%le ;.C Blow rates of feed to umene olumn after s ale up 'en:ene 5riginal . aled up (S 10) =.?C)I06 C8.> 16.8 D.>; ??.8 =.?C)I0C (umene mIDI-' pIDI-' Total

C.8D>C1DD 1.68DC;8=6

0.D>=8C??; ?.?8

5.C.) REFL.B RATIO OPTIMIAATION The num%er of tra!s is fi4ed at an! *alue sa! 1>. The feed tra! lo ation is *aried "eeping the num%er of tra!s fi4ed. Now for ea h different ratio of num%er of tra!s to feed tra! lo ation a series of reflu4 ratio starting from 0.1 is onsidered. The pro ess is run and the mole fra tion of %en:ene in the top produ t as well as the re%oiler heat load data are used and Big. ;.1D is o%tained %! plotting.

31

Big ;.1D Reflu4 ratio *s 1ole fra tion of umene in top produ t

Big ;.1> Reflu4 ratio *s mol fra tion and re%oiler heat load (ompared to %en:ene olumn the umene olumn performs %etter at higher *alues of reflu4 ratio. It an %e e4plained easil! %e ause the T4! diagrams for umeneIDI-' s!stems are thinner than T4! diagrams for 'en:eneIDI-' and hen e separation is diffi ult. The plots
32

o%tained in Big. ;.1D and ;.1> are similar in stru ture to those for %en:ene. Brom the plots a optimum reflu4 ratio of 0.? is identified. 5.C.5 FEED TRAY LOCATION OPTIMIAATION A pro ess similar to that des ri%ed in ;.>.; is followed.

Big. ;.16 Beed tra! lo ation *s 1ole fra tion of umene in top produ t

Big ;.1C Beed tra! lo ation *s Re%oiler heat load It an %e identified from Big. ;.16 and ;.1C that the optimum num%er of tra!s< feed tra! lo ation is 1><C.> or =<1.
33

5.C.4 N.MBER OF TRAYS OPTIMIAATION The all a%o*e parameters are "ept fi4ed and the num%er of tra!s is *aried "eeping the ratio fi4ed.

Big ;.18 Num%er of tra!s *s mole fra tion of umene in top produ t

Big. ;.1? Num%er of tra!s *s re%oiler heat load The optimum num%er of tra!s an %e identified to %e =0 from Big. ;.18 and ;.1?.

34

5.C.@ DISTILLATE RATE OPTIMIAATION Now "eeping other onditions fi4ed the distillate rate is *aried.

Big ;.=0 Distillate rate *s mole fra tion of umene in top produ t

Big ;.=1 Distillate rate *s mIDI-' and pIDI-' mole fra tions in top produ t If heat of re%oiler data whi h in reases in a straight line has *er! less effe t then the distillation rate an %e safel! optimi:ed to %e at C> "mol,hr or C.> "mol,hr (without s aleup). The plot o%tained in Big. ;.=0 and ;.=1 are similar to those for %en:ene olumn. It an %e
35

seen that the &ualit! of the top produ t in reases on in reasing the distillate rate %ut upto a ertain optimum distillate rate onl!. 5.7 RES.LTS OF OPTIMIAATION The results o%tained in the urrent optimi:ation pro0e t ha*e %een summari:ed %elow in the form of a %rief flowsheet in Big. ;.==.

Big ;.== Blow rates and other parameters o%tained %! optimi:ation.

36

CHAPTER 4

CONCLUSIONS

37

4. CONCL.SIONS A step %! step optimi:ation pro edure is followed in the present wor". The %asi omponents

of a umene plant are (1) Rea tors and (=) .eparators. )a h unit is optimi:ed %! ma4imi:ing the &ualit! of the desired produ t as well as its flow rate. This pro edure is adapted from Douglas Do trine (Douglas Doctrine. The osts of raw materials and produ ts are usuall! mu h larger than the osts of energ! or apital in a t!pi al hemi al pro ess. Therefore the pro ess must %e designed (in*esting apital and pa!ing for energ!) so as to not waste feed sto "s or lose produ ts (parti ularl! in the form of undesira%le produ ts) L6u!%en# =010M). After a unit is optimi:ed# optimum flow rates are o%tained. These flow rate *alues are used for optimi:ing the ne4t unit. The rea tor s!stem is optimi:ed %! an e&uili%rium %ased approa h. The optimum *alues of temperature and feed on entrations are o%tained as ;60 degree ( and 6<1 %en:ene< -rop!lene ratio respe ti*el!# %! ma4imi:ing the sele ti*it! towards umene. The on*ersion of the limiting reagent is also ma4imi:ed. The effe t of presen e of inert is also studied. The separator s!stem design %egins with the plotting of A6) ur*es for possi%le mi4tures. It an %e on luded from the A6) plots that separation is easier for %en:eneI umeneIDI-' s!stem. Blash distillation is tried %efore a tual fra tional distillation as the operating osts are *er! low. The optimum temperature for flashing is estimated. The distillation olumns i.e. %en:ene olumn and umene olumn depend on a large num%er of *aria%les (high degree of freedom). )a h *aria%le is optimi:ed %! "eeping the other *alues onstant. After an optimum *alue of a *aria%le is o%tained the remaining *aria%les are optimi:ed using that data. The num%er of tra!s is found to %e =0 for %oth while the feed tra! lo ation is 8 for %en:ene distillation olumn and 10 for umene olumn. Reflu4 ratios are o%tained as 0.> and 0.? respe ti*el!. The flashing temperature of the flash distillation tan" is found to %e ?=.> degree (. The flow rates and distillate rate data are shown in the optimised flow sheet gi*en in the pre*ious hapter. Rea tor and distillation olumn design re*ealed a lot of design onsiderations. Bor e4ample in distillation olumn design if distillate rate is in reased the produ t &ualit! and the flow rate of the desired produ t in rease %ut after a ertain *alue (optimum *alue) the produ t &ualit! and
38

flow rate redu e drasti all!. .imilar findings were o%tained while optimi:ing other units and the! ha*e %een dis ussed %riefl! in the pre*ious pages. Again design solution annot %e onsidered a%solute. Bor e4ample if we de rease the rea tion osts# the separation osts tend to in rease. The design should not onl! ta"e ost into onsideration %ut also other fa tors su h as safet!# en*ironmental impa t# future needs et .

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REFERENCES 1. 'uda*ari# ..# The 1er " Inde4# 11th ed.# Rahwa!# N3# 1er " V (o.# In .# p. D10 ed. (1?8?). =. (a*ender# B.# Aromati h!dro ar%ons. In< (la!ton# E.D. V (la!ton# B.).# eds.# -att!Ws Industrial 2!giene and To4i olog!# Dth ed.# Aol II# New @or"# 3ohn 8ile! V .ons# In .# pp. 1;0DI1;0># 1;D6I1;D? (1??D). ;. (hen 2siI3en# 6in @ehI(hin.# (ase .tudies on 5ptimum Reflu4 Ratio of Distillation Towers in -etroleum Refining -ro esses# Tam"ang 3ournal of . ien e and )ngineering# Aol. D# No. =# pp. 10>I110 (=001). D. (umene (A. ?8I8=I8# NT- Nomination 2istor! and Re*iew. >. Dimian A. (.# Integrated Design and .imulation of (hemi al -ro esses# )lse*ier (=00;). 6. Diwa"er +. 1.# 1adha*an /.-.# 5ptimi:ation of 1ulti omponent %at h ditillation olumns# Industrial )ngineering and (hemistr! Resear h# 1011I101C(1?8?). C. Bu 3.# Ding (.# .tud! on al"!lation of %en:ene with prop!lene o*er 1(1I== :eolite atal!st %! in situ IR# (atal!sis (ommuni ations# CC0PCC6(=00>). 8. 6ei G# Dai (# 8ang @# and (hen '# -ro ess 5ptimi:ation on Al"!lation of 'en:ene with -rop!lene# )nerg! V Buels =;# ;1>?P;166# =00?. ?. 6ei G# @ang 3# Eao 3# (hen '# 6i (# EasPli&uid and gasPli&uidPsolid rea tors for the al"!lation of %en:ene with prop!lene# (hemi al )ngineering . ien e# C;=0 P C;=6 (=00C). 10. 6ewis# R.3.# .r. 2awle!Ws (ondensed (hemi al Di tionar!# 1=th ed.# New @or"# Aan Nostrand Reinhold (o.# pp. ;=8I;=? (1??;). 11. 6ide D.R.# (R( 2and%oo" of (hemistr! and -h!si s# C6th ed.# 'o a Raton# B6# (R( -ress# In .# p. ;I>>(1??>). 1=. 6innhoff '.# Townsend D. 8.# 'oland D.# 2ewitt E. B.# Thomas '.# Eu! A. R.# 1arsland R. 2.# +ser Euide on -ro ess Integration for the )ffi ient +se of )nerg!# The Institution of (hemi al )ngineers (1??D). 1;. 6u!%en 8. 6.# Design and (ontrol of the (umene -ro ess# Industrial )ngineering and (hemistr! Resear h D?# C1?PC;D (=010).

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1D. 6u!%en 8. 6.# Distillation Design and (ontrol +sing Aspen .imulation# 8ile!# New @or" (=006). 1>. 1 (a%e# 8 6.# .mith# 3. (.# 2arriott# -.# +nit 5perations of (hemi al )ngineering# .i4th )dition# 1 ErawI2ill 2igher )du ation (=001). 16. . hmidt R. 3.# Industrial (atal!ti -ro essI-henol -rodu tionJ Applied (atal!sis A< Eeneral =80# 8?P10;(=00>). 1C. . hmidt# R. 3.# Gar h! A. ..# and -eterson E. A.< New De*elopments in (umene and )th!l%en:ene Al"!lation# AI(h) .pring 1eeting# New 5rleans# 1ar h =00=. 18. . hul:# R.(.# Aan 5pdorp# -.3. V 8ard# D.3.# (umene. In< /ros hwit:# 3.I. V 2oweI Erant# 1.# eds.# /ir"I5thmer )n ! lopedia of (hemi al Te hnolog!# Dth ed.# Aol. C# New @or"# 3ohn 8ile! V .ons# In .# pp. C;0IC;6 (1??;). 1?. .ride*i +# -radhan N. (.# Rao '. /. '.#.at!anara!ana (. A.# Rao '. ..# Al"!lation of 'en:ene with isoprop!l al oholo*er .A-5I> atal!st in an integral pressure rea tor# (atal!sis letters Aol. C?# Nos. 1ID# April =00=. =0. Turton# R.# 'ailie# R. (.# 8hiting# 8. '.# .haelwit:# 3. A. Anal!sis# .!nthesis and Design of (hemi al -ro esses# =nd ed.J -renti e 2all< +pper .addle Ri*er #N3#=00;.

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