Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
CHAPTER 1 ...................................................................................................... 2
INTRODUCTION .............................................................................................. 2
1.1 Introduction .......................................................................................... 2
1.2 Physical properties ................................................................................ 2
1.3 Chemical properties ............................................................................... 3
1.4 Supply and Demand .............................................................................. 4
1.5 Production Technologies ........................................................................ 6
CHAPTER 2 .................................................................................................... 11
MATERIAL AND ENERGY BALANCE........................................................... 11
2.1 Introduction ........................................................................................ 11
2.2 Block Flow Diagram ........................................................................... 11
2.3 Material Balance ................................................................................. 12
2.4 Energy Balance ................................................................................... 16
CHAPTER 3 .................................................................................................... 20
REACTOR SIZING CONSIDERING MAIN REACTION ................................... 20
3.1 Reactor Sizing According Algorithm ..................................................... 20
3.2 Catalyst Determination ........................................................................ 23
3.3 POLYMATH Result ............................................................................ 24
REFERENCES ................................................................................................ 28
CHAPTER 1
INTRODUCTION
1.1
Introduction
Ethylbenzene is an organic compound with the formula (C6H5CH2CH3) also
1.2
Physical properties
Under ordinary conditions, ethylbenzene is a clear, colourless liquid with a
ingestion, respiratory effects such as throat irritation and lung constriction, irritation
to the eyes and skin adsorption. The physical properties of ethylbenzene are as
follows (Ullmman''s, 1985) :
Table 1.1: Physical properties of Ethylbenzene
No.
1
Density
2
3
Melting Point
Boiling Point
Refractive Index
5
6
7
8
Critical Pressure
Critical Temperature
Flash Point
Auto Ignition Temperature
Flammability Limit
10
Latent Heat
11
Heating Value
12
Kinematic viscosity
13
Surface tension
14
1.3
Properties
At 150C
At 200C
At 250C
At 101.3 KPa
At 200C
At 250C
lower
upper
fusion
vapour ization
gross
net
At 37.80C
At98.90C
Ideal gas,250C
Liquid,250C
0.87139 g/cm3
0.8669 g/cm3
0.86262 g/cm3
-94.9490C
136.1860C
1.49588
1.49320
3609 KPa
344.020C
150C
4600C
1.0%
86.3 J/gm
335 J/gm
429999 J/gm
40928 J/gm
0.6428x10-6 m2/s
0.390x10-6 m2/s
28.48 mN/m
1169 J kg-1 K-1
1752 J kg-1 K-1
Chemical properties
Chemically, it is a monocyclic alkylaromatic compound with a 106 of
molecular weight. It is miscible with most of the commonly used organic solvents in
any ratio, but is only sparingly soluble in water (170 ppm under ambient conditions).
Spilled ethylbenzene will float on water and partition strongly towards air. No
significant environmental hazards are expected due to its high evaporation rate.
Being rather volatile and having a flash point of 19-23 C, ethylbenzene is
classified as a highly flammable substance, which in use may form flammable or
explosive vapour-air mixtures. The most important commercial reaction of
Ethylbenzene is its dehydrogenation to styrene. The reaction is carried out at high
1.4
odor and high inflammability. So that it is widely used in the petrochemical industry
in manufacturing of styrene.
Styrene is used mostly important applications of ethylbenzene that were
manufactured
mostly in polymer
production for polystyrene, acrylonitrile-butadiene-styrene (ABS) and styreneacrylonitrile (SAN) resins, styrene-butadiene elastomers and latexes, and unsaturated
polyester resins..
It is also used as an intermediate material in the production of plastic products
and is utilized as one of the basic raw materials in the production of various
chemicals. Ethylbenzene also a good solvent which it have in different sectors like in
the rubber industry, ink industry, the major markets of the styrene ware include
packaging, electrical/electronic/appliances, construction and consumer products.
The global demand for ethyl benzene is growing wherein the Asia Pacific
region has retained more than 47% of the market. China is the largest consumer and
producer of ethyl benzene, having a market share of 28%. It is because, the value of
Ethyl Benzene were so high that will give benefit to the industry to produce more
product that were linked to Ethyl Benzene.
This shows that the Ethyl Benzene (EB) is quite an important chemical
product that has a lot of uses to the industry. Based on analysis, The Asia-Pacific is
the biggest market of benzene consuming a significant share of the total consumption
in 2012, and it is also the second fastest growing market next to ROW. The
consumption patterns of benzene and its various derivatives are continuously showing
an upward trend which is mainly due to the shift of manufacturing industry to the
Asia-Pacific on account of increasing demand and low cost of production. China is
the leading country in the region in terms of both, production as well as consumption
of benzene and its derivatives, while the Indian market, despite being small in size, is
expected to be a market with high potential (PRNewswire , New York, June 19,
2014).
Figure 1.1 shows the consumption of Ethyl benzene in the world in 2013. The
world consume the EB about 99% to produce a lot of variety product that will
generate economy and about 1% consumed of ethylbenzene is used for other
applications.
For instance, global demand for ethyl benzene amounted to 28,567,852 tons
in 2014 (BGI research, 2012). The global EB market was dominated by the AsiaPacific region, with the domestic markets in developing economies expanding
exponentially (Global Chemical Price, 2013). The increasing standard of living and
increased styrene capacities across the globe increased the usage of EB in a number of
countries. With demand recovery expected in developed markets and increasing
demand expected from developing economies, overall global EB demand is expected
to have reached 34,667,874 tons by 2020 (GBI Research, 2012). Figure 1.2 shows
global demand trends for EB in volume terms from 2000 to 2020.
Figure 1. 2: Global Demand Trends for EB in volume terms from 2000 to 2020 by
GBI Research (2012)
1.5
Production Technologies
Currently, almost all ethylbenzene is produced commercially by alkylating
benzene with ethylene. There are different manufacturing processes available for
ethylbenzene .Some these are listed below:
1.5.4
liquid phase technologies except for the design of the alkylation reactor which combines catalytic reaction with distillation into a single
operation.
Table 1.2: The Comparison for Production Technology of Ethylbenzene. (Shenglin Liu, March 2009)
Properties
Operating
Temperature
Operating
Pressure
Conversion
Phase
Catalyst
Advantages
Vapour-phase Zeolite
Alkylation
400-450 C
450 to 600 C.
100%
The high-activity catalyst allows
transalkylation and alkylation to
occur simultaneously in a single
reactor
100%
100%
Zeolite Catalyst
Zeolite Catalyst
Zeolite Catalyst
i.
Use of zeolite catalyst
that eliminated issues associated
with corrosion and waste
disposal of aluminium chloride
ii.
The original vapour
phase design accomplished the
i.
The liquid phase
zeolite catalyst process
operates at substantially
lower temperature decreased
side reactions dramatically
resulting in ultra-high purity
i.
Combines catalyst
reaction with distillation into
single operation
ii.
The exothermic heat
of reaction creates
vaporisation necessary to
fast in presence of
Aluminum chloride
&produces almost
stoichiometric yields of
Ethylbenzene.
iii.
Essentially 100%
of ethylene is converted
i.
Handling and
disposal of aluminium
chloride catalyst and waste
has become increasingly
more costly and
complicated because of
environmental
considerations
Disadvantages
ii.
Equipment and
piping corrosion and
fouling along with related
environmental issues led
to development of EB
process based on solid
acid heterogeneous
catalysts
i.
The significant extent of
isomerisation reactions and
catalyst deactivation by
deposition of carbonaceous
material are most important
problems associated with high
temperature
ii.
The length of time
between regeneration can vary
from as little as 2 months to
slightly more than 1 year
depending on specific plant
design and operating conditions
iii.
Because the reactors
must be taken off line for
regeneration ,on-stream
EB product
ii.
The plant achieve
high on stream efficiency
often greater than 99% which
results in low turnaround &
maintenance cost
iii.
EBZ-500 catalyst has
operating length of more than
8year without catalyst
regeneration
iv.
The regeneration is
mild carbon burn procedure
that is relatively inexpensive
effect distillation
iii.
Capable of using
dilute ethylene feed e.g. Off
gas from a fluid catalytic
cracking plant or dilute
ethylene from steam cracker
iv.
In general ethylene
feed streams containing
significant amounts of
hydrogen, methane or ethane
do not require some pretreatment. (David Netzer,
1999)
iii.
Major equipment
pieces needed to replace
on regular schedule
because of corrosion
which results in extensive
turnarounds poor plant onstream efficiency and thus
are primary contributors to
the high operating costs
associated with aluminium
chloride
From above advantages & disadvantages for different processes we select Vapour Phase Zeolite Catalyst process (UOP). Since it has
more advantages over other existing manufacturing process for Ethylbenzene. Not only that, it also have long catalyst run-length with excellent
stability which can minimizes plant downtime, and It has highly selective reaction that are insignificant amount of xylenes are produced,
providing a highest product quality. Also it requires less pure benzene & ethylene. Less harm full to environment also. (technology, 2012)
CHAPTER 2
2.1
Introduction
This chapter will focus on calculation of material and energy balance for
----- (1)
However, there is another inevitable reaction takes place at the same time as
reaction (1) which is to produce diethylbenzene (C6H4(C2H5)2), an unwanted product.
C6H5C2H5 + C2H4 C6H4(C2H5)2
2.2
----- (2)
2.3
Material Balance
As this is mini project for Chemical Reaction Engineering II, we will consider
the material balance in the reactor only. Analysis of material balance follows the
extent of reaction method. The symbols 1 and 2 are used to denote the extents of
reaction for the first and second reaction, Equation (1) and Equation (2) respectively.
The material balances of all chemical species are generally computed using
the correlation as follows:
i = 0 + vi 1 -----(3)
where i is molar flow rate of the species i and vi is the stoichiometric coefficient. The
summary of using extent of reaction is as in Table 2.1.
Table 2.1: Material Balance Summary
Species
Benzene
Ethylene
Ethylbenzene
Diethylbenzene
Inlet
FB
FE
0
0
Change
- 1
- 1- 2
1- 2
2
Outlet
0
0
PEB
PDEB
Yield is 99.99%
Ethylene
Ethylene inlet into the reactor, FE = FFE + (1 - X)
= FFE/X
= PEB/YX
= 47.09/0.99 (0.9)
n2
= 52.85 kmol/hour
= 5.29 kmol/hour
Benzene
For PEB,
n5
==
= 47.09 kmol/hour
= 158.55 kmol/hour
= 110.99 kmol/hour
Diethylbenzene
Diethylbenzene outlet from the reactor, PDEB=PEB/YX * (1-0.99)
= 47.09/0.99 (0.9) * (0.01)
n6
= 0.53 kmol/hour
The results of calculations are tabulated as in Table 2.3. It is shown from total
of mass balance, the calculation is considered balanced.
Table 2.3: Summary of Mass Balance.
Species
Benzene
Ethylene
Ethylbenzene
Diethylbenzene
Total
Inlet
(kmol/hour)
158.55
52.85
0
0
211.4
Outlet
(kmol/hour)
110.99
5.29
47.09
0.53
163.9
Inlet
(kg/hour)
12384.3405
1482.4425
0
0
13866.783
Outlet
(kg/hour)
8669.4289
148.3845
4999.5453
71.1366
13888.4953
2.4
Energy Balance
In this part, only energy balance in the packed bed reactor will be calculated
accordingly. Figure 2.2 shows input-output structure of temperature in the said reactor, where
temperature feed is at 298K, while the temperature outlet is 573K. The reactor operates at
573K and 5000 kPa.
Kinetic energy, potential energy and shaft work change for these streams will be
neglected and only enthalpy changes take place. Hence the energy balance equation
equal to Q = H
Ideal properties for evaluating the energy balances of the process streams. This means
the pressure effect can be neglected.
Figure 2.3 shows structure of enthalpy path of reaction from 298K to 573K, where H
is enthalpy change of the reaction, Hrxn is heat of reaction of benzene and ethylene to
ethylbenzene at 298K and HP, 1 denotes enthalpy change of ethylbenzene from 298K to
573K.
As both ethylene and benzene enter in gas phase at 298K (Smith, 1925), no heat of
vaporization is required. To aid the calculation, thermodynamic properties is tabulated as in
Table 2.4.
Table 2.4: Thermodynamic Properties of the Species Involved (Smith, 1925)
Species
C2H4 (Ethylene)
C6H6 (Benzene)
C6H5C2H5 (Ethylbenzene)
A
1.424
-0.206
1.124
B (103)
14.394
39.064
55.380
C (106)
-4.392
-13.301
-18.476
: 52510 J/mol
: 82930 J/mol
: 29920 J/mol
From equation above,
Hrxn = 29920 82930 52510
Hrxn = -105520 J/mol
[ ]
The total heat of reaction of benzene, ethylene, ethylbenzene from 298 K to 573 K
HP,1 =
C6H6 +
C2H4 +
C6H5C2H5
= Hrxn + HP,1
= -105520 +11729.63
= - 93, 790.37 J/mol
CHAPTER 3
REACTOR SIZING CONSIDERING MAIN REACTION
3.1
Mechanism,
Adsorption:
Surface area:
Desorption:
Rate law,
Adsorption:
Surface area:
Desorption:
]
]
( )
( )
( )
[
( )
Site balance,
[
]
substitute (1),(2),(3)and (5) into (4)
( )
]
[
],
Stoichiometry
Species
Benzene
Inlet
Ethylene
Ethylbenzene
Rearranging
Change
Outlet
(
)
Concentration
(
)( )
)( )
)( )
Pressure
)(
)(
)(
Where
4
6.344 X 10
k1 [kmol/m3 cat/h/atm2 ] 0.69 10 6 exp
RT
162 ,730
K A [atm -1 ] 1.2328 10 17 exp
RT
35,368
K B [atm -1 ] 2.0850 10 4 exp
RT
4
3.933X 10
K A [atm-1 ] 1.5202 10 2 exp
RT
Design Equation
Rate law
[
Stoichiometry
(
Combine
3.2
Catalyst Determination
It is chosen that zeolite is the catalyst for this Ethylbenzene production. And its
Dp
= 0.0005 m
Void fraction
= 0.45
= 1.6404 x 10-3 ft
Ac
= 1.2928 m3/s
gc
Therefore,
(
(
(
)(
)(
)(
)
)(
3.3
( )(
)(
)(
(
)(
)
)
)
)(
)(
POLYMATH Result
In order to find the weight of catalyst, the simulation is ran by using Polymath
)]
POLYMATH Report
No Title
30-Dec-2014
3.482E-06
3.482E-06
3.482E-06
3.482E-06
-0.1666667
-0.1666667
-0.1666667
-0.1666667
Fao
158.55
158.55
158.55
158.55
k1
1.136199
1.136199
1.136199
1.136199
Ka
0.0084311
0.0084311
0.0084311
0.0084311
Kb
0.3494354
0.3494354
0.3494354
0.3494354
Kc
-3.949E-06
-3.949E-06
-3.949E-06
-3.949E-06
Pa
5000.
5000.
Pao
5000.
5000.
5000.
5000.
10 Pb
2.5E+04
2.372E+04
2.5E+04
2.372E+04
11 Pc
5993.528
5928.934
12 R
8.314
8.314
8.314
8.314
13 r1
-1.842766
-1.842766
14 rT
-1.842766
-1.842766
15 T
573.
573.
573.
573.
16 W
8100.
8100.
17 X
1.
1.
18 y
1.
0.9881557
1.
0.9881557
Differential equations
1 d(X)/d(W) = -rT/Fao
design equation for packed bed reactor
2 d(y)/d(W) = - A * (1+(E*X))/(2*y)
Explicit equations
1
Fao = 158.55
Pao = 5000
E = -1/6
R = 8.314
T = 573
Kb = 2.085*10^(-4) * exp(35368/(R*T))
14 A = 3.482*10^(-6)
alpha
15 rT = r1
General
Total number of equations
17
15
Elapsed time
0.000 sec
Solution method
RKF_45
0.000001
W
0
22.95491
40.55491
49.35491
58.15491
66.95491
84.55491
93.35491
102.1549
110.9549
128.5549
137.3549
146.1549
154.9549
172.5549
181.3549
190.1549
198.9549
216.5549
225.3549
234.1549
242.9549
260.5549
269.3549
278.1549
286.9549
304.5549
313.3549
X
0
0.2396088
0.3891483
0.4539301
0.5126204
0.565648
0.656403
0.6949469
0.7294536
0.7602877
0.8122901
0.8340773
0.8534292
0.8705981
0.8992874
0.9112068
0.9217439
0.9310528
0.9465244
0.9529215
0.9585615
0.9635323
0.9717691
0.9751658
0.9781561
0.9807882
0.9851426
0.9869357
X calc
0.767278907
0.774224554
0.779549923
0.782212608
0.784875292
0.787537977
0.792863346
0.795526031
0.798188713
0.800851397
0.806176767
0.808839451
0.811502136
0.814164821
0.81949019
0.822152875
0.82481556
0.827478244
0.832803614
0.835466298
0.838128983
0.840791668
0.846117037
0.848779722
0.851442406
0.854105091
0.859430461
0.862093145
X residual
0.767278907
0.534615754
0.390401623
0.328282508
0.272254892
0.221889977
0.136460346
0.100579131
0.068735113
0.040563697
-0.006113333
-0.025237849
-0.041927064
-0.056433279
-0.07979721
-0.089053925
-0.09692834
-0.103574556
-0.113720786
-0.117455202
-0.120432517
-0.122740632
-0.125652063
-0.126386078
-0.126713694
-0.126683109
-0.125712139
-0.124842555
X residual ^2
0.588716922
0.285814004
0.152413427
0.107769405
0.074122726
0.049235162
0.018621426
0.010116162
0.004724516
0.001645414
3.73728E-05
0.000636949
0.001757879
0.003184715
0.006367595
0.007930602
0.009395103
0.010727689
0.012932417
0.013795724
0.014503991
0.015065263
0.015788441
0.015973441
0.01605636
0.01604861
0.015803542
0.015585663
From Table 3.1, at approximately 90% conversion the weight of catalyst required is
172.55 kg. Hence, analyzing the reactor sizing,
AC = 0.0144 ft2 = 0.0013378 m2
(
)(
= 106.60 m
= 17.76 m
It is determined that the length of the reactor is 106.6 m while its diameter is 17.76 m
REFERENCES
David Netzer, 1. H. (1999). "Mixed Phase Ethylene Process for Manufacturing Ethylbenene".
U.S.Patent, 977,423.
ICIS. (2011, August). Retrieved from Ethylbenzene (EB) Prices and Pricing Information:
http://www.icis.com/resources/news/2007/11/02/9075692/ethylbenzene-eb-pricesand-pricing-information/
iHS Chemical. (2012, October). Retrieved from
http://www.ihs.com/products/chemical/planning/ceh/ethylbenzene.aspx
Klaewkla, R., Arend, M., & Hoelderich, W. F. (2011). A Review of Mass Transfer
Controlling the Reaction Rate in Heterogeneous Catalytic Systems. InTech.
Petronas. (2014). Retrieved from http://www.petronas.com.my/ourbusiness/downstream/petro-chemicals/Pages/other-petro-chemical-plants.aspx
Polimeri Europa. (n.d.). Retrieved from
http://www.eni.com/it_IT/attachments/azienda/attivitastrategie/petrolchimica/licensing/Ethylbenzene-fl-lug09.pdf
Scorecard. (n.d.). Retrieved from http://scorecard.goodguide.com/chemicalprofiles/uses.tcl?edf_substance_id=100-41-4
Shenglin Liu, F. C. (March 2009). "Highly selective ethylbenzene production through
alkylation of dilute ethylene with gas phase-liquid phase benzene and transalkylation
feed". Journal of Natural Gas Chemistry, 21-24.
Smith, J. M., Van Ness, H. C., & Abbott, M. M. (2005). Introduction to Chemical
Engineering Thermodynamics. New York: Mc Graw Hill Education.
technology, w. (2012, - -). Ethylbenzene/Styrene Monomer. Retrieved oktober 14, 2014, from
Ethylbenzene/Styrene Monomer.
Turton, R., Bailie, R. C., Whiting, W. B., Shaeiwitz, J. A., & Bhattacharya, D. (2013).
Analysis, Synthesis, and Design of Chemical Processes (Fourth ed.). United States:
Pearson Education.
Ullmman''s. (1985). Ethylbenzene. Encyclopedia of Industrial Chemistry, vol. 12 pp-519-530.
Vincent A.Welch, K. J. (2005). Ullman's Encyclopedia of Industrial Chemistry. Weinhem:
Wiley-VCH.
Vincent AVincent A.Welch, K. J.-P. (2005). Ethylbenzene. Wiley-VCH, Weinheim:
Ullmans Encyclopedia of Industrial Chemistry.