Benzene Production Using Shale Gas

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E.
Soh
H83DPX Design Project Final Report

Production of Benzene from Shale Gas through
Integrated Non-Oxidative Dehydroaromatization.
MODULE CODE
GROUP
ACADEMIC SUPERVISOR
INDUSTRIAL SUPERVISOR
DATE OF SUBMISSION
AUTHORS
NAME
Arati Banu A/P Verasingham
H83DPX
4
Prof Dominic Foo
Mr. Rafil
18th April 2016
STUDENT ID
013802
Chan Joel Kai Chin
011032
Fidelia Prasetya
Kim Tae Yeon
Soh Yi Shin Elaine
011494
013461
013332
PROGRAMME
MEng Chemical Engineering
MEng Chemical with
Environmental Engineering
BEng Chemical Engineering
Department of Chemical Engineering, University of Nottingham Malaysia Campus,

Selangor, Malaysia
I | Page
A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh
Table of Contents
Section I. Extended summary ...................................................................... 1
I.1
Executive Summary .................................................................... 1
I.2 Group Appraisal ................................................................................. 2

I.3 Individual Appraisal ............................................................................ 2
Appraisal of Individual Design - Arati Banu ......................................... 2
Appraisal of Individual Design - Joel Chan .......................................... 2
Appraisal of Individual Design - Kim Tae Yeon ..................................... 2
Appraisal of Individual Design - Soh Yi Shin Elaine .............................. 3
Appraisal of Individual Design - Fidelia Prasetya.................................. 3
Section II. Design Basis .............................................................................. B
II.1 Feedstock Capacity and Specifications ................................................. 4
II.2 Production Capacity Specifications ....................................................... 4
Section III. Process Background...................................................................C
III.1
Production Overview ..................................................................... 5
III.2
Application and Uses .................................................................... 6

Benzene ........................................................................................ 6
Toluene.......................................................................................... 6
Naphthalene ................................................................................... 6
III.3
Market Survey ............................................................................. 7

Benzene ........................................................................................ 7
Toluene.......................................................................................... 8
Naphthalene ................................................................................... 8
III.4
Physical and Chemical Properties ................................................... 9
III.5
Review of Alternative Processes ................................................... 10

III.5.1 Process 1: Non-oxidative Dehydroaromatization ..................... 10
III.5.2 Process 2: NonOxidative Plasma Conversion of Methane to Acetylene Subsequent Dehyd
o-aromatization Process to Benzene ................................................ 12
III.6
Economic Potential Evaluation...................................................... 15
III.7
Selection Criteria........................................................................ 16
Process Selection .......................................................................... 16
III.8 Site Selection ................................................................................ 18

III.8.1 Supplier and market connection ............................................ 18
II | P a g e

III.8.2 Labour Cost ....................................................................... 19
III.8.3 Occupancy and construction costs ......................................... 19
III8.4 Tax Rates ............................................................................ 20
III8.5 Energy and water availability ................................................. 21
III8.6 Site Selection Justification ..................................................... 21
III8.7 Site Location Selection ......................................................... 21
III.9
Plant Layout ............................................................................. 23
Section IV. Mass and Energy Balances ......................................................... D

IV.1
Process Flow Diagram (PFD) ........................................................ 24
IV.2
Process Description .................................................................... 25

Process Description ....................................................................... 25
Overall Assumptions: .................................................................... 26
Basis and Assumptions for Energy Balance ....................................... 27
IV.3
Mass Balance ............................................................................. 28

Flash 1(FV-101) ............................................................................ 28
Membrane separator (MR-101) ....................................................... 30
Distillation Column 1 (DC-101) ....................................................... 31
MEA Scrubber (SC-101) (4) ............................................................. 32
MEA Solvent Regenerator (ST-101) (4) .............................................. 33
Mixing Point ................................................................................. 34
Reactor 1 (RX-101) ....................................................................... 35
Reactor 2 (RX-102) ....................................................................... 36
Flash 2 (FV-102) ........................................................................... 37
Pressure Swing Adsorption Unit (PS-101-PS-104) ............................. 38
Purge .......................................................................................... 39
Crystallizer (CR-101) ..................................................................... 42
Heat Exchanger ............................................................................ 43
Expander ..................................................................................... 43
III | P a g e

Compressor.................................................................................. 43
Reactor........................................................................................ 43
Reboiler and Condenser ................................................................. 44
Pump .......................................................................................... 44
Crystallizer ................................................................................... 44
IV.5 Comparison: Manual Mass Balance and Simulation ............................. 45
ENERGY COMPARISON BETWEEN MANUAL AND SIMULATION ..................... 46
Justification For Mass Balance ................................................................. 47
Justification For Energy Balance .............................................................. 47
Section V. Energy Recovery and Utilities ..................................................... 48
V.1 Introduction .................................................................................... 48
V.2 Pinch Analysis and Heat Exchanger Network Design ............................. 48
V.3 Grid Diagram .................................................................................. 51
V.4 PFD AFTER HEAT INTEGRATION ........................................................ 53
V.5 UTILITY BALANCE and ENERGY AUDIT (Follow the UPDATED PFD AFTER
HEAT INTEGRATION) ............................................................................. 54
V.6 Cost of the Utility ............................................................................ 55
V.7 Steam Distribution ........................................................................... 56
V.7.1 Steam Generation System ..................................................... 56
V.8 Cooling Water System ...................................................................... 56
V.9 Chilled Water System ....................................................................... 57
Section VI. Individual Equipment Design ..................................................... 58
VI.1 Equipment Design for DC-101 .......................................................... 59
VI.2 Equipment Design for SC-101 .......................................................... 66
VI.2.1.General Sizing and Overview ................................................ 64
VI.2.2. Internal supports and packing materials ................................ 64
VI.2.3. External supports ............................................................... 65
VI.2.4. Data Specification Sheet ..................................................... 68
VI.2.5. Scrubber drawing ............................................................... 69
VI.3 Equipment Design for RX-101 .......................................................... 66
VI.3.1 Overall Summary of Equipment Design........................................... 70
VI.3.2.1 Predicted Chemical Reaction Kinetics ........................................... 71
VI.3.3 Individual Equipment Design Basis & Considerations ........................ 72
VI.3.3.1 Selection of Type of Reactor ....................................................... 72
IV | P a g e

VI.3.3.2 Mass & Energy Balance as Starting Point for Design Basis &
Considerations ...................................................................................... 73
VI.3.4 Mass Balance Algorithms & Equipment Specification Calculations ....... 73
VI.3.4.1 Mass & Energy Balance Algorithms in MATLAB .............................. 73
VI.3.4.2 Discussion and Findings from Graphs Obtained through MATLAB
Algorithm ............................................................................................. 74
VI.3.4.3 Reactor Specification Calculations ............................................... 74
VI.3.5 Equipment Loading Sheets and Drawing Sketches
VI.3.5.1 Equipment Loading Sheet .......................................................... 74
VI.3.5.2 Equipment Drawing Sketches ..................................................... 76
VI.3.5.2.1 Explaining Drawing Sketches ................................................... 76
VI.3.6: Extensive Individual Equipment Design Appraisal and Suggested
Further Improvements ........................................................................... 76
Drawing Sketches VI.3.5.2.1 - 3.5.2.3 ........................................................ 77
VI.4.1 Drawing of DC-102 .............................................................. 82
VI.6 General Arrangement Drawing ......................................................... 89
VI.7 List of Equipment and Load Sheet..................................................... 90
VI.8 Scheduling of Equipment (Pump)...................................................... 93
Section VII. Environmental Protection ......................................................... 94
VII. Environmental Protection ................................................................. 94
VII.1 Introduction (Environmental Management) ....................................... 94
VII.3 Environmental Impact Assessment (EIA) & Leopold Matrix ................. 96
VII.3.1 Environmental Impact Assessment (EIA) ....................................... 96
VII.3.2 Leopold Matrix ......................................................................... 100
VII.3.2.1 Findings from Leopold Matrix ................................................. 100
VII.3.2.2 Leopold Matrix Table .............................................................. 100
VII.4: Managing, Handling, Treating & Disposal of Waste Products ............ 100
VII.4.1: Waste Streams Channelled to Wastewater Treatment Plant .......... 100
VII.4.2 Waste Streams Disposed by Thermal Oxidizers ............................ 101
VII.4.3 Disposal of Deactivated MO/HZSM5 catalyst ................................ 101
VII.4.4 Storing & Handling of CO2 ........................................................ 101
VII.4.5 Waste Stream Recycled as Fuel Gases for RX-101 ........................ 101
VII.4.6 Purified Hydrogen Gas Handling & Disposal .................................. 101
VII.5: Basic Waste Effluent Treatment Plant Design ................................. 102
VII.5.1: Brief Introduction of Engineering Challenge and Approach for Solution
102
V | Page

VII.5.3 Basic Mass Balance Calculation & Sizing of Wastewater Treatment Plant
Sizing 103
VII.5.3.1 Mass Balance and Sizing for Bioreactors (BR-101 & 102): ........... 103
VII.5.3.2 Mass Balance for Secondary Clarifier (CR-101): ......................... 104
VII.5.3.3 Mass Balance for Ultrafiltration Membrane (MR-102): ................. 104
VII.6: Review & Adhering to Local Environmental Legislation .................... 104
VII.6.1 Local Ambient Air Quality Standards ........................................... 104
VII.6.2 Environmental Quality for Surface Water Standards (GB 3838-2002)
105
VII.7 Cleaner Production Strategies ....................................................... 105
VII.7.1 Less Carbon Soot Production by RX-101 with Membrane Technology
Integration for H2 Gas Removal ............................................................. 105
VII.7.2 Storing & Handling of CO2 through Selling of CO2 for Industrial Usage
Or Biogenic Capture Via Microalgae Cultivation in Open Pond .................. 105
VII.7.3 Waste Stream Recycled as Fuel for Heating of RX-101 .................. 106
VII.7.4 Supply of Purified Hydrogen Gas to a Neighbouring Plant for
Commercial Hydrogen Gas ................................................................... 106
VII.8 Conclusion.................................................................................. 106
Section VIII. Process Safety .................................................................... 112
VIII.1. Introduction ............................................................................. 107
VIII.2. HAZARD & OPERABILITY STUDY (HAZOP) .................................... 107
VIII.3. Emergency Response (Evacuation) Plan ....................................... 108
Objective ................................................................................... 108
Plant layout ................................................................................ 110
VIII.4. Bow-Tie Diagram ...................................................................... 110
Section IX. Process Operation and Control................................................. 115
IX.1: Executive Summary .................................................................... 115
IX.2: General Standard Operating Procedures (SOP) Manual..................... 115
IX.2.1: Plant Prestart-up Safety Review ......................................... 115
IX.2.2 General Plant Start-up Procedure ........................................ 116
IX.2.3 General Plant Normal Operation Guideline ............................ 116
IX.2.4 General Plant Shut Down Procedure..................................... 116
IX.2.5 Abnormal/Emergency Response ................................... 116
IX.3 Standard Operating Procedures (SOP) for Equipment ........................ 116
IX.3.1 Flash (FV-101 and FV-102) ................................................. 116
IX.3.2 Dehydrator Column (DH-101 and DH-102) ........................... 117
IX.3.3 Distillation Column (DC-101, ST-101, DC-102, DC-103 and DCVI | P a g e

104) .......................................................................................... 118
IX.3.4 Reactor (RX-101 and RX-102) ............................................. 119
IX.3.5 MEA Scrubber (SC-101) ..................................................... 120
IX.3.6 Pressure Swing Adsorption Unit (PSA) .................................. 121
IX.3.7 Crystalliser (CR-101) ......................................................... 122
IX.3.8 Furnace (F-101 and F-102) ................................................. 123
XI.4 Control Philosophy and Strategy ..................................................... 124
XI.4.1 Control System for Distillation Column with Total Condenser (DC103) .......................................................................................... 124
XI.4.2 Control System for Distillation Column with Partial Condenser (DC
-102) ........................................................................................ 125
XI.4.3 Control System for Reactor (RX-101) ................................... 127
XI.4.4 Control System for Flash (FV-101)....................................... 128
XI.4.5 Control System for Compressor(C-101) ................................ 129
XI.4.6 Control System for Dehydrator (DH-101 and DH-102) ........... 130
XI.4.7 Control System for Furnace (F-101)..................................... 131
XI.4.8 Control System for MEA Scrubber (SC-101) .......................... 132
XI.4.9 Control System for Crystalliser (CR-101) .............................. 133
XI.4.10 Control System for Pressure Swing Adsorption Unit (PSA) ..... 134
XI.5 Piping and Instrumentation Diagram (P&ID) .................................... 137
Section X. Economic Evaluation ............................................................... 139
Executive Summary ............................................................................. 139
X.1 Fixed Capital Investment ................................................................ 139
X.1.1 ISBL ................................................................................. 139
X.1.2 OSBL ................................................................................ 141
X.1.3 Cost of Land and Infrastructure. ........................................... 142
X.1.4 Cost of engineering, contingency and location ........................ 143
X.1.5 Total Fixed Capital Investment ............................................. 143
X.2 Working Capital ............................................................................. 143
X.3 Variable Cost ................................................................................ 143
X.3.1 Raw Material ...................................................................... 143
X.3.2 Utilities ............................................................................. 144
VII | P a g e

X.3.3 Consumables ..................................................................... 145
X.3.4 Effluent Discharge .............................................................. 145
X.4 Fixed Cost of Production ................................................................. 145
X.5 Revenue ....................................................................................... 146
X.5.1 Increase in Revenue after the Environmental Analysis ............. 146
X.6 Tax and Depreciation ..................................................................... 146
X.7 Profit and ROI ............................................................................... 146
X.8 Cash Flow Analysis ........................................................................ 147
X.9 Net Present Value .......................................................................... 148
X.10 Simple Pay-Back Time .................................................................. 148
X.11 Discounted Cash Flow Rate of Return ............................................. 149
X.12 Rate of Return ............................................................................. 150
X.12 Economic Evaluation Summary ...................................................... 150
VIII | P a g e
Section I. Extended summary
MODULE CODE
GROUP
ACADEMIC SUPERVISOR
DATE OF SUBMISSION
AUTHORS
NAME
H83DPX
4
Prof Dominic Foo
Mr. Rafil
25th November 2015
STUDENT ID
0138802
Chan Joel Kai Chin
011032
Fidelia Prasetya
Kim Tae Yeon
Soh Yi Shin Elaine
011494
013461
013332
PROGRAMME
MEng Chemical with

Selangor, Malaysia
I.1
Executive Summary
The proposed process of the modular benzene manufacturing plant from shale
gas is through an integrated non-oxidative dehydroaromatization process. The
common dehydroaromatization utilizes a single catalyst that converts methane
and ethane to benzene. The integrated process however uses 2 distinct catalyst
namely; Mo/HZSM-5 and Mo2C/ZSM-5. Both the catalyst convert methane and
ethane to benzene except Mo/HZSM-5 favours a higher conversion of methane
whereas Mo2C/ZSM-5 favours the conversion of ethane. This simultaneously
maximizes the overall product yield in a single conversion step.
This modular plant is located in Tarim, China. The plant operates 365 days in a
year for 2 years before shutting down for maintenance for 2 to 3 months. The
overall product yield is 34.9%.
A feed flow of 48,180 MT/year produces 48,180 MT/year of Industrial Grade of
99.82 wt% of benzene. Besides that, the selected process also produces 93.51
wt% of HD-5 Grade propane, 99.86 wt% of Industrial Grade hydrogen, 99.91
wt% of Industrial Grade naphthalene and 90.87 wt% of Commercial Grade
toluene to further sustain and diversify the plant economically. Three of which
have more than six carbons. The estimated annual gross profit of the plant is
637,402,457.40 USD/MT of benzene.
Generally, shale gas can cause major residual injuries and requires preheating
before it can be ignited. Benzene is a stable, flammable and toxic chemical which
can ignite under ambient condition. Apart from that continuous heat is required
to maintain the reactors at 700C, posing a threat to the workers. Carbon
dioxide is emitted from the plant after being purified according to the laws of the
local Environmental Protection Agency (EPA). With strict implementation of the
China Occupational Safety & Health Association (COSHA) regulations the plant
can operate safely.
1 | Page
I.2 Group Appraisal

The entirety of the design project was very overwhelming. The benzene
manufacturing process selected enabled a passage for creative-critical thinking
among the group members. The design project showcases the importance of
team work in designing a functional economic plant. One of the main factors
identified was that each General Aspect was required to work hand in hand to
produce a feasible plant. One of the most important factors of any plant includes
the safety factor. The safety analysis conducted allowed the group to brainstorm
possible design mistakes of which could contribute to fatality which worked hand
in hand with the suggested process control system. The effect on the
environment and the performed heat integration was compared with the
economics of the plants diligently to ensure a high performing petrochemical
plant. Among the difficulties faced includes selecting the holdup time for the
manual sizing of all the minor equipment while still obeying the standard safety
margins. The SOP manual contributed to a great deal of difficulties due to the
lack of resources however it was overcome by sheer determination.
I.3 Individual Appraisal
Appraisal of Individual Design - Arati Banu
Designing the distillation column had a positive effect on my outlook of Chemical
Engineering. One of the challenges that stimulated my brain was solving the
distillation column weeping problem whilst simultaneously ensuring that the
general specifications were met. The detailed calculations performed were
tedious but it provided a pathway to understanding the working principle of a
distillation column with a much greater depth. Apart from that, the drawing of
the column enabled the identification of flaws made. After which, the said flaws
were tackled.
Appraisal of Individual Design - Joel Chan
One of the main challenges faced in this endeavour is to find the chemical
reaction kinetics that gives promising product yield. This is because this process
is scarcely studied and researched upon. However, after many simulation trials it
was found that this process still yields low product similar to most literature
findings. Despite of this challenge, an innovative method has to be employed to
maximize heat absorption due to endothermic nature which promises higher
product yield. A deep appreciation should be given to Dr. Suchithra and my
friends who have endearingly helped me to complete this design.
Appraisal of Individual Design - Kim Tae Yeon
When designing the scrubber, at first I did not know how to start with. There was
lack of information on scrubber design and especially that for carbon dioxide
with Mono-ethylamine. Most of chemical engineering design books focused and
concerned on distillation columns or heat exchangers. One of group member
gave me an information that it was quite direct forward and simple to calculate
the height and diameter. She also taught the guiding book that I could refer to.
However, carbon dioxide reacted with mono-ethylamine in the scrubber. It was
unlike the other packed bed distillation columns or normal scrubbers. It made
the calculations much more complicated and different for some parameters.
However, I found an example for carbon dioxide and MEA scrubber design. This
2 | Page
example was very helpful. It was hard to find a way to measure pressure drop
for scrubber design. As far as I saw, I could select the desired pressure drop to
find the number of stages, height and diameter. Confusingly, few articles showed
different types of equations to derive the pressure drop of scrubber. However, I
still doubt if the pressure drop can be measured or it is one of the parameter to
decide the specific design of the scrubber. After I design the scrubber, I was
supposed to compare my result with HYSYS. However, there was not suitable
fluid package I could choose for MEA with carbon dioxide. It discouraged the
evaluation of accuracy of the result. Better evaluation of the scrubber design can
be done if correct fluid package exists for MEA or other soft-wares to check the
reliability of the manual calculation.
Appraisal of Individual Design - Soh Yi Shin Elaine
I chose to design distillation column 3 (DC-103) as my individual equipment
design. Designing a distillation column is not easy as it involves many steps,
especially in hydraulics design. In certain steps of hydraulics design, iterations
are required in order to get the desired design. For instance, assumption on hole
areas needs to be revised if the actual minimum vapour velocity is below the
weep point. Besides, I had to ensure that residence time for both rectifying and
stripping section of column is greater than 3s. The calculations were revised
several times before desired outcomes were obtained.
Appraisal of Individual Design - Fidelia Prasetya
I have chosen distillation column (DC-102) as the equipment that I want to
design. To be honest, I have no confidence to design a reactor thus I chose this
equipment. At first, I was thinking that it was quite alright to design a distillation
column since there is a guideline step in the book. However, when it came to
design this equipment, I faced quite a lot of difficulties. There are some
uncertainties in design such as the diameter obtained for the column is quite
small and regarding the pressure drop in the column. Assumptions also need to
be made during the equipment design. By doing extra research, I am able to
overcome most of the problem and proceed with my design.
3 | Page
Section II. Design Basis

MODULE CODE
GROUP
ACADEMIC SUPERVISOR
DATE OF SUBMISSION
AUTHORS
NAME
Soh Yi Shin Elaine
Kim Tae Yeon
H83DPX
4
Prof Dominic Foo
Mr. Rafil
18th April 2016
STUDENT ID
013332
013802
013461
Chan Joel Kai Chin
011032
Fidelia Prasetya
011494
PROGRAMME
MEng Chemical with

Selangor, Malaysia
B | Page
II.1 Feedstock Capacity and Specifications

The selected feedstock for the production of benzene is shale gas. As a result of the recent
abundance of shale gas reservoirs as well as the positive impacts towards the suppliers and
consumers. The selected feedstock will be obtained directly through the shale gas reservoir
pipelines.
Table II.1: Feedstock Specifications.
Feed
Chemical Formula
Feed Rate
Feed Temperature
Feed Pressure
Grade
IUPAC ID
Phase
CAS Number
Feed
Specifications
124-38-9
7727-37-9
74-82-2
74-84-0
74-98-6
106-97-8
109-66-0
7732-18-5
Shale Gas
Unspecified
182,821.20 MT/year
20.87 MT/hour
48.9C
61.0 bar
No specification
Unclassified
Mixture
Percentage
(wt%)
0.16
0.53
58.36
21.33
11.22
5.90
2.21
0.32
Chemical
Name
Carbon Dioxide
Nitrogen
Methane
Ethane
Propane
Butane
Pentane
Water
II.2 Production Capacity Specifications

The overall production of benzene, produces useful by-products apart from the desired main
product.
Refer to AI.2 Design Basis Specifications for the production specifications for propane,
hydrogen, naphthalene and toluene.
Table II.2: Production Capacity of Benzene.
Product
Benzene
Chemical Structure
Chemical Formula
Production Rate
Grade
IUPAC ID
Phase
CAS Number
Benzene
Specifications
71-43-2
71-43-2
108-88-3
109-66-0
C6H6
48,180 MT/year
5.50 MT/hour
Industrial Grade 99.82%
Benzene
Liquid
Percentage
(wt%)
99.82%
99.85
0.01
0.06
Chemical
Name
Benzene
Benzene
Toluene
Pentane
4 | Page
Section III. Process Background
MODULE CODE
GROUP
ACADEMIC SUPERVISOR
DATE OF SUBMISSION
AUTHORS
NAME
Soh Yi Shin Elaine
Kim Tae Yeon
H83DPX
4
Prof Dominic Foo
Mr. Rafil
16th April 2016
STUDENT ID
013332
013802
013461
Chan Joel Kai Chin
011032
Fidelia Prasetya
011494
PROGRAMME
MEng Chemical with

Selangor, Malaysia
*Refer to AI.8 page 24 in the appendix for overall yield calculation.
C| P a g e
III.1 Production Overview

Shale
Gas
PreTreatment of
Shale Gas
Dehydrated
Stream
H2O
`
H2
Gases
Removal of
H2 Gases
C3H6, C4H8 &

C5H10
Separation &
Purification
Short Chain
of C3+
Gases
CO2 Gases
Removal of
CO2 Gases
Stripped CO2
Gases
Recycle
Stream
Light
Hydrocarbon
Separation of
Products from
Unreacted Feed
Benzene _
+
)
_
Side Products
Residual Gases
Benzene
Purification
of Products
Separation
of Benzene
Dehydroaromzatization
of Methane & Ethane to
Benzene
Toluene
Separation of
Toluene &
Naphthalene
Naphthalene
Figure III.1 Process Block Diagram of the Proposed Process.

Due to the advancement of new technologies found in drilling for crude oil, there
has been a recent abundance of shale gas. This review proposes an integrated
process to convert shale gas into benzene. Firstly, shale gas undergoes pretreatment to remove water. Then, the dehydrated stream is purified to remove
C3+ hydrocarbons. After which, carbon dioxide is stripped, as carbon dioxide
inhibits the catalyst.
The pre-treated stream then enters the dehydroaromatization reactors where
methane and ethane is converted to benzene; subsequently producing useful byproducts; hydrogen, naphthalene and toluene. Naphthalene is removed
consecutively to prevent crystallization along the stream. Light hydrocarbons are
separated from benzene and toluene followed by the removal of hydrogen gas.
The unreacted gas is recycled. Benzene and toluene is then purified and
separated; producing marketable final products. The table below outlines the
number of major equipment involved in this process.
Table III.1 Major Equipment Involved in the Process
Types of Major Equipment
Distillation Column
Reactor
PSA Unit
Scrubber
Stripper
Crystallizer
Quantity
4
2
1
1
1
1
The plant operates 330 days for 7920 hours/year until the scheduled
maintenance shutdown. The overall yield percentage of benzene is 46.7% with
marketable grades.
5 | Page
III.2 Application and Uses

Benzene
Benzene is widely used in the world as daily products such as plastics, dyes or
glues. It is a colorless and flammable liquid which has sweet odor similar to
gasoline. In the early 19th and 20th centuries, it was used as one of the
ingredients of after shaves due to its sweet smell. A German coffee merchant
used it to decaffeinate coffee in 1903. However, due to its carcinogenic property,
it is no more used in those areas. Nowadays, it is more likely to be used in
industries. For example, it is used for the manufacture of plastics, detergents,
resins, pesticides lubricants, rubbers or dyes. It is also one of the worlds most
important base chemical to produce other chemicals such as ethylbenzene,
toluene, phenol or cumene. It is also a major petrol component. Figure 2.1
shows the applications of benzene in 2014.
Figure III. 2: Global Benzene Demand by Application (2014) (Merchant Research

& Consulting ltd, 2015).
Toluene
Toluene has various commercial or industrial uses and applications. For example,
nail products consists of toluene to produce quick glossy film with evaporation.
In biochemical uses, it is used to damage the red blood cells for hemoglobin
extraction. As benzene is used for toluene synthesis, toluene is used for benzene
production. About 56% of the toluene production depends on the production of
benzene and xylene (Ceresana, 2015). One of the major products of toluene is
toluene diisocyanate or TDI. It is sued to form polyurethane foams. Those foams
are used in upholstery, mattresses or car seats. The minor products from toluene
are phenol, nitrobenzene or caprolactam. Octane booster in gasoline is also
made up of toluene.
Naphthalene
Naphthalene is well known for a household fumigant such as mothballs. In the
past, it was used for oral medication of the livestock to kill the parasitic worms.
It is also used as an intermediate chemical for the production of other chemicals
such as alkyl naphthalene sulfonates which is a famous wetting agents for paints,
coatings and various pesticide formulations. When it is substituted with other
functional groups such as amine or sulfonic acids, dyes are made. One of the
well-known uses is production of phthalic anhydride. This is used in the
production of dyes, insecticides or pharmaceutical products.
6 | Page
III.3 Market Survey

There are three products with more than 6 carbons produced in the selected
process. They are benzene, toluene and naphthalene. The market demands of
the products are high worldwide due to their various uses and applications.
Global markets and their prices are observed in this section.
Benzene
Benzene is the main product of the plant. The market grade of benzene is 99.9%
purity (David Netzer, 2003). A research from (Sean, 2008) said that in 2008,
Europe was the largest benzene consumption followed by U.S and China.
However, China started consuming the largest amount of benzene in the world
since 2013 followed by Unites States (Ceresana, 2014).
Benzene is demanded mainly by two types, either for ethylbenzene production or
cumene (iHS, 2014). The two makes up 70-75% of the benzene annual
consumption (iHS, 2014). Therefore, to compare the global consumption of
benzene, the world consumption of ethylbenzene in 2014 from figure 8.1.1 (iHS,
2014) can be used to find out the global consumption of benzene in 2014. As
shown, China, U.S. and Western Europe occupied nearly the half consumption of
the worlds benzene..
Figure III.4.1: World Consumption of Ethylbenzene in 2014.

China, USA and Western Europe consumes about 16-17% of global benzene
(Merchant Research & Consulting ltd, 2015). On the other hand, the market
demand of benzene is forecasted to increase up to 53432.9 Kilotons in China by
2018 (Dallas, 2014).
The global market of benzene dropped from January 2014 to December 2014
(Platts McGraw hill Financial,, 2014). However, the global benzene market is
forecasted to grow 3% (Merchant Research & Consulting ltd, 2015). The market
7 | Page
price of benzene in China on 15th November 2015 was 4400 RMB/m3 (Commodity
Data Group, 2015) which is equal to 2.61 USD/gallon while in US in November
2015 was 2.17 USD/gallon (ICIS, 2015).
Toluene
There are three grades of toluene in the market. They are TDI grade (99%
purity), nitration grade (98.5-100% purity) and commercial grade (92-96%
purity). In 2006, the world demand of toluene was 23 MTones (ICIS, 2007). The
global demand of toluene is different across the world and it is shown in Figure
8.1.2 (iHS, 2013). As shown, China dominates the worlds largest consumption
of toluene followed by United States and Republic of Korea in 2012. Toluene
market price in China on 16th November 2015 was 5787.50 RMB/m3 (Commodity
Data Group, 2015) which is equal to 3.4 USD/gallon and in U.S. 831 USD/MT
(Market Watch,, 2015) which is equal to 2.73 USD/gallon.
Naphthalene
The technical product which contains naphthalene should be at least 95% purity
of naphthalene (WORLD HEALTH ORGANIZATION, 2002). Most of naphthalene is
consumed in China as shown in figure 8.1.3 (iHS, 2013).Its price on 16th
November 2015 achieved 409.7 USD/ton (Quotent, 2015) in Europe.
Figure III 4.2: Global Toluene

Consumption in 2012.
Figure III.4.3: Global Naphthalene

Consumption in 2012.
8 | Page
III.4 Physical and Chemical Properties

Table III.5: Physical and Chemical Properties of the Products Produced (NCBI, 2015).
Main Products
Molecular Formula
Molecular Weight (g/mol)
CAS-Number
Exact Mass (g/mol)
Heavy Atom Count
Formal Charge
Complexity
Physical Description
Benzene
C6H6
78.11
71-43-2
78.05
6.00
0.00
15.50
Liquid
Colour
Odour
Boiling Point (C)
Melting Point (C)
Flash Point (C)
Critical Temperature (C)
Critical Pressure (bar)
Critical Density (kg/m3)
Vapor Pressure (mm Hg at 25C)
Auto-Ignition (C)
Explosive Limits (%)
Odour Threshold (ppm)
Colourless
Aromatic
80.08
5.56
-11.00
288.85
48.90
302.00
94.80
498.00
1.2 - 7.8
4.68
Toluene
C7H8
92.14
108-88-3
92.06
7.00
0.00
42.00
- Gas
Vapor,
Liquid
- Liquid
- Wet Solid
Colourless
Aromatic
110.60
-94.60
4.00
319.85
41.00
264.00
28.40
480.00
1.1 - 7.1
2.14
Naphthalene
C10H8
128.17
91-20-3
128.06
10.00
0.00
80.60
- Liquid
- Crystals
Propane
C3H6
44.10
74-98-6
44.06
3.00
0.00
0.00
Liquid
White
Aromatic
217.90
80.20
79.00
474.85
41.00
315.00
0.09
526.00
5.90
0.30
Colourless
Odourless
-42.10
-187.60
-104.00
96.74
42.51
220.48
7150
450.00
2.37 - 9.5
5000.00
Hydrogen
H2
2.02
1333-74-0
2.02
0.00
0.00
0.00
- Gas
Vapor,
Liquid
- Liquid
- Wet Solid
Colourless
Odourless
-252.77
-259.00
93.00
-240.01
12.96
31.263
1.24x106
500.00
1.27
0.00
9 | Page
III.5 Review of Alternative Processes

The world has abundant reserves of methane, especially with the recent
discoveries of significant deposits of shale gas in continental North America as
well as China. Methane, the most abundant compound in natural gas, can be
converted catalytically to liquid fuels or useful chemicals. As world reserves of
readily accessible petroleum are progressively depleted, methods for efficient
use of methane are becoming more important. The two major routes to produce
valuable chemicals from methane, indirect and direct conversion. Direct
conversion of methane to benzene or other valuable chemicals is a very
promising process for the efficient application of natural gas.
III.5.1 Process 1: Non-oxidative Dehydroaromatization
Number of Conversion Steps
Conversion Method
Type of Reaction
Mode
Catalyst
Status
:
:
:
:
:
:
1
Direct
Endothermic
Continuous
Mo/HZSM-5
Patented
Brief Overview
This is a method for selective conversion of methane directly to benzene and
hydrogen without participation of oxygen. This makes hydrocarbons
synthesized from methane more expensive than the analogs obtained from
crude
oil.
The
reaction
product
distribution
of
the
methane
dehydroaromatization is very complicated. In addition to light aromatics
(mainly benzene) and naphthalene, there is also little amount of polyaromatics.
Methane dehydro-aromatization over Mo/HZSM-5 catalysts in a continuousflow mode has received attention recently (CATALYSIS REVIEWS, 2015). Many
catalysts have been evaluated, with the intention of finding ways to enhance
the reactivity, stability and/or selectivity to aromatics in general and to light
aromatics in particular. Most of the studies came to the same conclusion that
the Mo/HZSM-5 catalyst is the best one among the tested catalysts (Spivey,
James J.,,2014).Overall, there is still plenty of room to further improve the
processes of one-stage methane conversion.
Process Description
Recyle
Shale Gas
Pre-Treatment of
Shale Gas
Methane
+
Ethane
C3+ compounds, water,

carbon dioxide
Reactor
Benzene
+
By-products
Separator 1
Benzene Storage
Benzene
By-products
Separator 2
By-products
By-Products
Storage
Figure III.5.1 Block Diagram on Process 1.

Pre-Treatment
The shale gas is purified by a series of separators to remove propane, butane,
pentane, carbon dioxide and water. This process is essential to ensure maximum
efficiency of the process.
[*Please refer to AI.3 for alternative processes 3, 4 and 5 ]
10 |P a g e
Reactor
The mixture of mainly methane and ethane is fed to the reactor at 700C and
3.3 bar over a fixed-bed reactor with Mo/HZSM-5 as a catalyst to produce the
desired benzene along with toluene, naphthalene, and hydrogen.
Selectivity and Yield:
Table III.5.1.1 Selectivity and Yield of Process 1.
Catalyst
Reactant
Co.
(%)
CH4
10.6
C2
C6H6
Selectivity
C10H8
C
0.033
0.588
0.198
0.025
0.720
0.167
C7H8
C3H6
0.181
0.086
0.002
Mo/HZSM-5
C2H6
20.8
Chemical Reactions:
3 C2H6 2 C3H6 + 3 H2
(Equation III.5.1.1)
C2H6 C2H4 + H2
3 C2H6 C6H6 + 6H2
5 C2H6 C10H8 + 11H2
7 C2H6 2 C7H8 + 13H2
6 CH4 C6H6 + 9H2
2 CH4 C2H6 + H2
10 CH4 C10H8 + 16H2
CH4 C + 2H2
Overall Reactor Balanced Equation:

19CH4 + 18C2H6
2C H
6
+ 2C10H8 +2C7H8 + 2C3H6
+ C2H4 + C2H6 + C + 62H2
Separators
The separation unit is used to separate and purify the products to the required
chemical grade. Hydrogen is removed using a pressure swing absorption unit
(PSA) whereas benzene, toluene, naphthalene and propane are separated using
distillation coloumns. This enables the products to be sold at the current market
rate.
Safety and Environmental Impact
The overall safety aspect of this process is deemed safe. The pre-treatment and
separation processes occur at moderate, low risk conditions. Even though the
reaction operates at 700C and 3.3 bar; a high risk condition, with proper safety
11 |P a g e
procedures and strict implementation this issue can be dealt with (CATALYSIS
REVIEWS, 2015). For instance, thick vessel walls are required.
With accordance to the NFPA 704 fire diamond in Section AI.3 Safety Evaluation,
benzene and toluene are noted as flammable at high temperatures, hazardous
and stable; Code 2-3-0. Naphthalene is noted as flammable at high
temperatures, highly toxic and stable; Code 2-2-0. This process will have
adverse effects to the environment if the waste chemicals are released to the
environment without being in compliance with the local Environmental Protection
Agency (EPA).
Process 1 overview
Table III.5.1.2 Pros and Cons on Process 1.
Pros
Cons
Single Step Conversion
Thermodynamically unstable
(without suitable catalyst)
Low operating cost
Complex Reaction Product Distribution
Low capital cost
Reaction occurs at high temperature

(700C)
Alternative Hydrogen Production

Method
Absence of Gas-Phase Oxidants
III.5.2 Process 2: Non-Oxidative Plasma Conversion of Methane to
Acetylene Subsequent Dehydo-aromatization Process to Benzene
Conversion Method
Type of Reaction
Mode
Catalyst
Status
:
:
:
:
:
:
2
Indirect
Endothermic
Continuous
NaY Zeolites and Palladium Typed Catalyst
Patented
Brief Overview
The first process would be to convert shale gas which consists mainly of
methane to acetylene through a non-oxidative method that operates at a low
temperature. This process utilizes electrical field and charge effect of
hydrogen/helium plasma to produce acetylene. After which, acetylene is
converted to benzene which is the final targeted product by the
cyclotrimerization process that utilizes a palladium typed catalyst.
12 |P a g e
Process Description
Pre-Treatment of
Shale Gas
Shale Gas
Methane
Reactor 1
Reactor 2
Acetylene
Benzene
+
intermediates

carbon dioxide
Benzene Storage
Benzene
Purification
Recyle
By-Products
By-Products
Storage

Pre-treatment
Firstly, the shale gas that has been extracted will undergo similar pretreatment
process where water is first removed by using flash drums and glycol separators.
The higher chain alkane gases are extracted shortly after, leaving clean methane
gas which will be channeled to the first reactor.
Reactor 1
The first reactor uses the non-oxidative conversion method which operates by
applying corona discharge effect to convert methane to acetylene (Kalthchev et
al., 1999).
Catalyst
NaY-Zeolite
Co. of
Methane (%)
30.2
C2 Selectivity (%)
C2 Yields (%)
47.2
14.2
Reactor 2
After the stream passes through the first reactor, the product stream coming out
will be channeled to the second reactor that converts acetylene to benzene using
palladium typed catalyst (Liu, Mallinson and Lobban, 1998).
Chemical Reactions:
A. Production of
Acetylene via Methane through
Conversion Method in Low Temperature Plasma (NaY)
(i)
e(>10eV) + CH4 CH3 + H
(ii)
CH3 + CH3 C2H6
(iii)
C2H6 C2H4 + H2
(iv)
C2H4 C2H2+ H2
Non-Oxidative Plasma
Zeolites (1st Reactor)
B. Production of Benzene via Acetylene through a Palladium Typed Catalyst (2nd

Reactor)
(i) (CH2=C=) + C2H2 C4H4
(ii) C4H4 + C2H2 C6H6
Overall Reactor Balanced Equation:
6CH4 + C2H2 C6H6 + C2H6 + C2H4 + 6H2
13 |P a g e
Purification
The streams that contains mainly benzene and acetylene undergo a purification
process which separates unreacted methane, ethane and acetylene is recycled
back to feed stream in reactors, while gases from side reactions such as ethane,
ethylene, acetylene and hydrogen are extracted out by using distillation columns.
Seeing as this process produces hydrogen gas, it will be utilized in the 1st reactor
that requires hydrogen/helium plasma, hence a pressure swing method is
utilized to separate hydrogen from benzene.
Storage
Pure benzene is subsequently stored in storage vessels.
Safety and Environmental Impact
The safety aspect of Reactor 1 focuses on the conversion of methane to
acetylene on the operating condition at moderate temperature and pressure.
Therefore, heat and pressure parameter risk potential are at minimal. However,
high voltage of electricity is needed to produce the corona discharge effect of the
hydrogen/helium plasma that is crucial for the conversion reaction to take place.
This poses a high risk in the operation of the reactor as the leakage of electricity
might cause electrocution hazards and pose as an ignition source for the
intermediate products. The safety aspect of Reactor 2 focuses on the conversion
of acetylene to benzene at safe operating condition due to low temperature and
pressure condition.
benzene is noted as flammable at high temperatures, hazardous and stable
(Code 2-2-0). Acetylene is noted Code1-4-3. Acetylene does not ignition easily
however it is extremely toxic and may cause death and capable of detonation at
elevated temperatures and pressures. Ethene on the other hand is noted as
Code 2-4-2; meaning it is not easily ignited, extremely deathly and undergoes
violent changes at elevated temperatures and pressures.This process will have
adverse effects to the environment if the minimal allowable concentration
designated by the department of environment (DOE) is not obeyed.
Process 2 overview
Pros
Cons
Does not involve complicated heat

exchanger systems
(Less heat duty required)
High Capital Cost

(expensive catalyst)
Operates at low temperatures

(Maintains an optimal yield)
High Operating Cost

(ultrahigh vacuum conditions)
Less undesirable side reactions
High Energy Consumption
Double Step Conversion
14 |P a g e
III.6 Economic Potential Evaluation

Refer to AI.4 Economic Potential Evaluation for detailed calculations on the gross
profit.
Table III.6: Gross Profit of Alternative Processes.
Process
Gross Profit (USD/MT)
4000.79
1050.82
3
4
455.91
4511.31
3486.48
Based on the gross profit from Table III.6, it is perspicuous that Process 4 has
the highest gross profit followed by Process 1 and Process 5.
In terms of economic feasibility, Process 4 would be the most suitable process
followed by Process 1 and 5.
Annual Gross Profit

(Process 4)
= (20.87 of Feed MT/hours) x (365 days)

x (24 hours) x (4511.31 USD/MT)
= 824,763,107.80 USD/MT
Annual Gross Profit

(Process 1)

x (24 hours) x (4000.79 USD/MT)
= 731,429,228.70 USD/MT
Annual Gross Profit

(Process 5)

x (24 hours) x (3486.48 USD/MT)
= 637,402,457.40 USD/MT
15 |P a g e
III.7 Selection Criteria

Process Selection
In order to factor all the possible criteria into the process selection, the design
team proposed 2 rating systems; Rating System A and Rating System B.
Rating system A, evaluates each criteria that is required to be high for the most
feasible process. Rating System B, evaluates each criteria that is required to be
low for the most feasible process.
Hence, the most suitable process should register a high rating A but a low rating
B.
Rating System:
High
Average
Low
3
2
1
Table III.7.1: Process Criteria Rating System A.

Evaluation Criteria
Catalyst Availability
Overall Product Yield
Product Selectivity
Overall Conversion
Production of Useful
By-Products
Gross Profit
Total
Process
1
2
2
2
1
Process
2
2
1
2
1
Process
3
2
1
1
1
Process
4
2
2
2
2
Process
5
2
3
2
2
3
13
2
10
1
8
3
13
3
15
Table III.7.2: Process Criteria Rating System B.

Evaluation Criteria
Step Conversions
Energy Consumption
Process Complexity
Environment &
Safety Impact
Capital Cost
Operating Cost
Total
Process
1
1
2
1
Process
2
2
3
2
Process
3
3
3
3
Process
4
3
3
2
Process
5
1
2
1
1
2
8
3
3
16
3
3
17
2
2
13
1
2
8
Please refer to AI.4 and AI.5 for equipment and catalyst selection.
16 | P a g e
Process Selection Justification:

Based on the catalyst required Mo/HZSM-5 , N a Y- Ze o l i t e , 0.5 wt% Zn/NZ,
Li2CO3/ZnO and Mo2/HZSM-5 it was found that these are specialty catalysts and
cannot be purchased off the market. Availability of the catalyst depends on the
local supplier. This makes each catalyst equally available provided the catalyst
has been patented or commercialized. Based on the Tables in Section III 5.1.1,
III 5.2.1, III 5.3.1 and III 5.4.1, it is evident that Process 1 and Reaction 3 in
Process 4 have the highest overall conversion complimented by a high selectivity
towards benzene. All the suggested alternative processes produce useful byproducts, however due to the added value of Naphthalene; 549.40 USD/MT
Process 3 and 4 surpass the other processes. Process 4 obtained the highest
gross profit of 4511.31 USD/MT, followed by Process 1 with a reduced profit of
11% and 22% for Process 5.
The higher the number of major equipments, the higher the capital cost. For
simplicity; the number of reactors required by each process was compared.
Processes 1, 2 and 5 require less than 2 reactors, which is very practical
compared to Process 3 which requires 5 reactors and Process 4 with 3 reactors.
Endothermic reactions generally consume more energy as compared to
exothermic processes. The endothermic processes are 1, 2 and 5; which require
a heating utility of either steam or thermal oil to maintain the reactions at the
optimal conditions. For instance reactors in Process 1 and 5 require a
temperature of 700C. Process 2 on the other hand, operates under vacuum
conditions. The complexity of each reaction depends not only on the number of
conversion steps but also the types of catalyst required and number of major
equipments.
All the processes except for Process 3 are relatively green processes. Process 3
produces carbon monoxide. With accordance to the NFPA 704 fire diamond in
Section AI.3 Safety Evaluation, Process 2 and 3 pose vital effects as the
processes produce chemical compounds that detonate easily, are highly unstable
and deathly. Process 1, 4 and 5 produce flammable but stable compounds.
With respect to Rating System A, Process 5 has the highest overall yield (high
conversion rate and high selectivity), produces useful profitable by-products to
further sustain the plant, apart from a high gross profit of 3486.46 USD/MT.
With regards to Rating System B, both Process 1 and 5 involve a single step
conversion; consume an acceptable amount of energy in comparison to the other
processes. This is because although the Processes 1 and 5 require continuous
heating but the other processes have high capital costs and operating costs due
to the increase in major equipment required and maintenance required. Both
process 1 and 5 have minimal effects to the environment and are safer in
comparison to the other processes.
Table III.7.1 and III.7.2 showcase that Process 5 is the most feasible process;
registering a high Rating A and a low Rating B. Based on the aforementioned
reasons, the design team has selected Process 5 for the production of benzene
from shale gas.
Please refer to AI.4 and AI.5 for equipment and catalyst selection.
17 | P a g e
III.8 Site Selection

There are few things to be considered before choosing the location of the plant.
Some critical factors for the site selections from (Dale , 2014) are shown below.
(1) The supplier and market connection
(2) Labor Costs and Quality Dilemma
(3) Occupancy and construction costs
(4) Tax rates
(5) Energy availability
III.8.1 Supplier and market connection
Supplier connection
One of the most important considerations to determine the site of the plant is
the distance from the raw material. Distant transportation of the voluminous raw
materials at a certain feed condition is costly and inefficient. Moreover, if the
distance from the raw materials is far, the just-in-time supply of the shale gas
may not be promised as it would require a much longer pipeline. Any trouble or
delay of the raw material supply causes problems in production. It is closely
related and crucially affects the profit. Therefore, careful research must be done
to choose a right location near the shale gas. The top 10 countries with shale
gas resources are shown in figure 8.1 (EIA, 2014).
Figure III.8.1:
Top 10 Countries with Recoverable Shale Gas Resources.
The top 4 countries with abundant shale gas resources are China, Argentina,
Algeria and United States. China however overwhelms Argentina, Algeria and
U.S.
Market connection
The plant is preferred to be built near the market of the products. They are
benzene, toluene and naphthalene. The transportation cost increases if the
markets are located further from the plant due to the differences in the
transportation methods. Moreover, keeping the products at the necessary
conditions for sale during the transportation requires high energy and cost.
18 | P a g e
In order to select the best country to set up the proposed plant, the global
market demand and the past consumption percentages of the products were
monitored. As discussed in III.3, the demand for benzene was greatest in China,
US and Western Europe. Toluene was in demand and consumed the highest in
China and US. The biggest naphthalene market was China and Asia countries.
Among the four selected countries with vast amounts of shale gas resources,
only China and United States have shown significant market demands for
benzene toluene and naphthalene.
China is considered superior as it is located near South Korea which is the 4th
biggest benzene-consuming country and 3rd largest toluene-consuming country.
III.8.2 Labour Cost
If the minimum wage of labour is expensive, the operating cost increases. High
operating cost results in less profit. Therefore, labour cost is one of the
important factors to be considered. Table 8.2 (Nation Master, 2012) indicates the
ranks of the top 10 countries with recoverable shale gas resources in ascending
order of labour wages.
Table III.8.2: Labout Cost of the Top 10 Countries with Recoverable Shale Gas
Resources.
Rank
Country
Labour (USD)
1
2
Central African republic

Russia
$ 0.17
$ 0.76
3
4
Mexico
China
$ 0.89
$ 1.73
5
6
Brazil
Algeria
$ 2.18
$ 2.27
7
8
U.S.
Canada
$ 7.25
$ 7.71
9
10
Argentina
Australia
$ 8.76
$ 10.63
Central African Republic has the cheapest labour cost followed by Russia and
Mexico. However, they are relatively low shale gas resources in these countries.
Hence, they were not considered for the site of the plant. On the other hand, the
highlighted countries refer to the top 4 countries with plenty of shale gases.
Among them, China provides the lowest labour cost followed by Algeria.
Argentina requires the highest labour cost. Therefore, Argentina was eliminated
from the considerations.
Therefore, China and Algeria are the two most preferable countries for the plant
in terms of labour cost.
III.8.3 Occupancy and construction costs
The land price and construction cost are also the important elements. They are
the variables determining the capital cost of the plant. Provision of relatively
inexpensive construction cost also means high opportunity cost. They are also
indirectly related to the profit margin due to the return of investment (ROI).
Figure 8.3 (Arcadis, 2014) shows the international construction cost comparisons
with UK as a standard. As shown, USA has higher construction cost compared to
19 | P a g e
China. The construction cost comparison factor of China is about 50 as compared

to the UK with a standard of 100. It is, however, less than 90 for USA. It is
approximately 1.8 greater than China.
In other words, building a plant in USA is expected to be about 1.8 times
expensive than in China.
Figure III.8.3: International Construction Cost Comparisons with UK as a

standard extracted from (Arcadis, 2014).
III8.4 Tax Rates
Tax rates affect the operating cost and the financial performance of the plant. In
some cases, the tax rebates or incentives can cover the tax rates. However, it
only offsets to a certain extent (Dale , 2014).
There are varieties of taxes. Some examples are personal income taxes
supported by the plant, sales taxes, estate taxes, corporate tax rates and , in
this case, the carbon emission taxes. It is crucial to find a place with low tax
rates. Among the various types of taxes, carbon tax rates of the different
countries mainly China and USA are observed in this study. Carbon taxes are
related to the level of carbon dioxide emissions. Different states of America and
provinces of China have different carbon tax rates. Figure 8.4 (Kristin Eberhard,
2014) shows the carbon tax prices by cities of the different countries over the
world. Table 8.4 shows the average carbon tax rates in China and USA. As shown,
China has overall lower average carbon tax prices compared to USA.
Table III.8.4: Average carbon tax rates of China and USA (Kristin Eberhard, 2014).
Country
Carbon Price (US dollars/ton)
China
7.43
USA
11.25
20 | P a g e
Figure III.8.4: Carbon Emission Tax Price per Country in 2014.

III8.5 Energy and water availability
Average industrial electricity price in China in 2013 was $142.714 (USD)/MWh
(Bloomberg New Energy Finance, 2014) while in U.S. it was $68.9(USD)/MWh in
2013 and $70.1(USD)/MWh in 2014 (U.S. Department of Energy, 2015).
Hence, it is clear that building the plant in USA is more cost efficient in terms of
electricity tariff.
Figure III.8.5: Average Water Tariffs in China and U.S.

The industrial water price of China and US vary with provinces and staes. Table
8.5.1 (CHANTAL MARCHESI, 2015) shows the average water tariff in the
different countries. U.S. has higher water tariffs than China.
Therefore, in terms of water prices, it is better to build the plant in China.
III8.6 Site Selection Justification
Considering the important factors of site selection, China is selected for the site
of the plant. It has the most abundant shale gas resources together with the
largest market of benzene, naphthalene and toluene. Moreover, it has low
minimum wage of the labours, tax rates, and construction cost and water tariffs.
III8.7 Site Location Selection
There are abundant shale gas basins in China. The two main basins are Sichuan
and Tarim basin (EIA U.S. Energy Information Administration, 2015). Figure 8.6
shows map of technically recoverable shale oil and shale gas basins in China
(Scott Stevens, 2013).
21 | P a g e
Figure III.8.7.1: Map of Shale Gas Resources in China (Scott Stevens, 2013).
Sichuan is a primary onshore region producing the natural gases. The most of
shale gas production in Sichuan is carried out by a company called CNPC. Its
production increased by five times from 2013 to 2014 (EIA U.S. Energy
Information Administration, 2015). However, Sichuan and the areas near there
have high risk of earthquakes. Many of the major earthquakes of China
happened in the Sichuan Province. For example, one of the tragic earthquake
stroke Sichuan in 2008 with a magnitude of 8.0 and an earthquake with
magnitude of 7.0 was occurred in 2013 in Sichuan Province.
Tarim basin was the second largest gas producing basin in China in 2014 and the
largest semi-closed inland basin in China (Anwaer Maimaitiming, 2013). About
400,000bbl/d of shale gas and oil was produced in 2014 from Tarim and other
key basins in Xinjiang (EIA U.S. Energy Information Administration, 2015).
Tarim is safer than Sichuan in terms of earthquakes. However, most of Tarim
basins experiences higher water stresses than Sichuan (Gwynn Guilford, 2014).
Fortunately, this problem can be solved by building the water tanks in the plant.
The transportation of the products is necessary inside the mainland of China as
the demand of the products in China is high. This can be done with railways in
Tarim and the trucks with the containers.
In conclusion, Sichuan Province has high risk of earthquake which cannot be
prevented or avoided by any means. On the other hand, Tarim basin has a risk
of drought due to high water stress but this can be overcomed by building water
tanks or water pipes in the plant.
Hence, Tarim is considered the most suitable to set up the plant.
Figure III.8.7.2: Map of Tarim.
22 | P a g e
III.9
Plant Layout
Control Room
PS101
MR-101
PS102
CV101
PSA Zone
PS103
Main
Entrance
Guard
House
FV102
FV101
Flash Zone
SC-101
Scrubber
+
Stripping
Zone
RX-101
PS104
RX-102
CR101
Maintenance
Workshop
Compressor & Expander Zone

Heat Exchanger Zone
Reactor Zone
DC-102
ST-101
Engineering
Building
DC-103
DC-104
Car Park
Raw Chemical
Warehouse
Distillation Zone
Cooling
Tower Zone
Chemical Storage (After QA)
Packaging Warehouse
Back
Entrance
Boiler Zone
Guard
House
Power
Generation
Zone
Weighing
Station
DC-101
QA Building
Loading & Unloading Bay
Assembly
Point
DH101
R&D Building
Finance, Marketing and

Administration Building
Chemical Shipping Warehouse
Company Hostel
Cafeteria
In-House
Clinic
23 | P a g e
Section IV. Mass and Energy Balances
MODULE CODE
GROUP
ACADEMIC SUPERVISOR
DATE OF SUBMISSION
AUTHORS
NAME
Soh Yi Shin Elaine
Kim Tae Yeon
H83DPX
4
Prof Dominic Foo
Mr. Rafil
18th April 2016
STUDENT ID
013332
013802
013461
Chan Joel Kai Chin
011032
Fidelia Prasetya
011494
PROGRAMME
MEng Chemical with

Selangor, Malaysia
D | Page
IV.1
Process Flow Diagram (PFD)
24 | P a g e
IV.2
Process Description
Process Description
Shale gas is fed into the plant at 996.30 kmol/hr and it is first pre-treated to
remove impurities such as water. Presence of water in feed is undesired as it
might damage the turbine due the formation of water droplets after expansion
process. Formation of hydrates also causes fouling as crystal residues build up
around the pipelines. In order to eliminate such problems, shale gas is cooled to
30oC in order to condense most of the water into liquid phase. The remaining
water vapour in the feed gas is removed in the dehydrator using silica gel as
adsorbent. A membrane separator (MR-101) is utilized to remove C3+
hydrocarbons from feed. The C3+ hydrocarbon streams will then enter
distillation column 1 (DC-101) so that propane can be separated from butane
and pentane and can be sold as side product. Then, the feed gas will enter
scrubber (SC-101). Mono-ethanol amine (MEA) solvent is used in the absorber
column (SC-101) to absorb the CO2 from the feed gas. CO2 removal is important
because CO2 is found to affect the catalytic conversion of methane and ethane in
the second reactor. The MEA solvent stream that contains dissolved CO2 will then
be fed into a stripper column for regeneration. The regenerated MEA solvent will
then be pumped back to previous absorber column to repeat the entire cycle.
Fresh feed will combine with the recycle stream before entering reactors.
Recycling is essential in our process as the methane conversion is relatively low.
In the reactors, methane and ethane are converted to benzene through dehydroaromatization. At the same time, side products such as naphthalene, toluene,
ethylene and propylene are produced. Both reactors are isothermal packed bed
reactors. Catalyst used in the first reactor is Mo/HZSM-5 while the second
reactor uses Mo2C/ZSM-5 to catalyse reaction. Both reactors are put in series to
maximize conversion of reactants. After reactors 1 and 2, a high pressure flash
is used to separate products from the unreacted feed gas. The unreacted feed
gas will then pass through pressure swing adsorption (PSA) unit before it is
recycled back to reactor 1. Not all the unreacted feed gas leaving PSA is recycled
back into the system. Approximately 8% of the unreacted feed stream is purged
in order to prevent accumulation of gases in the system.
Approximately 90% of the hydrogen present in the unreacted feed gas is
removed in the pressure swing unit. The pressure swing vessel contains layers of
various types of absorbents which are alumina, activated carbon and zeolites.
Alumina serves as the safeguarding layer to prevent the zeolite layer from being
damaged by water vapour. During adsorption, nitrogen in the unreacted feed will
be adsorbed into the pores of the zeolite absorbent while the other hydrocarbons
are adsorbed into the activated carbon. Hydrogen gas will not be adsorbed by
any of the layer and will leave from the top part of PSA. During desorption
process, the valves at the top of the pressure swing vessels are closed and
pressure is reduced so that the adsorbed components can be released.
Benzene, toluene and naphthalene leaving the high pressure flash will then be
sent to distillation columns for separation. In distillation column 2, light
hydrocarbons are removed from benzene, toluene and naphthalene in order to
reach the product industrial grade purity. Lastly, distillation column 3 is used to
separate benzene from toluene and naphthalene whereas distillation column 4 is
used to separate toluene and naphthalene. Naphthalene will be sent to
crystallizer to transform it to solid form.
25 | P a g e
Overall Assumptions:
1) No heat loss to the surrounding.
2) For distillation columns, all light non-keys will go to distillate while heavy
non-keys will go to bottom.
3) Only methane and ethane react in the reactors.
4) All reactions are gas phase reactions without a change in volume.
5) For energy balance, negative represent energy released and positive
represent energy supplied.
6) Coke formed(C) will deposit on the surface of catalysts and stay in the
reactor.
Basis and Assumptions for Mass balance
Table IV.2.1: Basis and Assumptions for Mass Balance by Equipment.
Equipment
Dehydrator
Membrane
Basis and Assumptions

Adsorbent: Silica gel
1. All water vapour is assumed to be removed from feed;
water present in the feed is minute. (Farag et al., 2001)
2. Water removed is adsorbed by silica gel and stay inside the
dehydrator.
1. Propane removal efficiency: 88%
2. Butane removal efficiency: 93%
3. Pentane removal efficiency: 95%
(A. Lokhandwala and L. Jacobs, 2000)
Catalyst: Mo2C/ZSM-5
Selectivity
C2H6 C6H6 C2H4
C
C7H8 CH4
0.075
0.1 0.85 0.05
0
0
0
0.672
0
0.42
0
0.02 0.11 0.45
(Solymosi and Szoke, 1998)
Reactant Conversion
Reactor 2
Methane
Ethane
Pressure
Swing
Adsorption
(PSA)
1. Hydrogen recovery= 90 mol%

2. Hydrogen purity= 99.99 mol% (remaining 0.01% is nitrogen
) (Baksh et al., 2002)
3. Ratio of adsorption pressure to desorption pressure follows t
he ratio of 4:1. (Kohl and Nielsen, 1997)
Distillation
Column 4
1.
2.
3.
4.
Light key is toluene and heavy key is naphthalene

Benzene recovery: 99%
LK in bottom: 0.01
HK in distillate: 0.012
26 | P a g e
Basis and Assumptions for Energy Balance

Table IV.2.2: Basis and Assumptions for Energy Balance by Equipment.
Equipment
Basis and Assumptions
Heat
Exchanger
1. Phase change will occur in two of the heat exchangers (HE-101

and H-104), thus latent heat of vaporization need to be
calculated. Critical Temperature for each difference, thus if the
temperature exceed the critical temperature of the component,
it is assumed that the latent heat of vaporization is 0
2. Latent heat of vaporisation (average) will be used to calculate
the heat of vaporization/condensation
Expander
1. Expander use polytropic process since the flowrate is high.

2. Polytropic efficiency is 65%
3. Estimation of adiabatic exponent using the estimated
inlet/outlet temperature.
4. Cp average will be taken for the calculation
1. Compressor use polytropic process since the flowrate is high.

2. Polytropic efficiency is 70%
Compressor 3. Estimation of adiabatic exponent using the estimated
inlet/outlet temperature.
4. Cp average will be taken for the calculation
Condenser
1. Partial condenser will be used for all distillation column

2. The proper value of optimum reflux ratio has been shown to be
between 1.2 to 1.5 Rm. However, sometime the value of reflux
need to be adjusted based on the number of stages needed. It
due to complete economic balance on the fixed cost of the
tower and operating cost.
3. Operating condition before and after the condenser is assumed
to be the same, thus only heat of vaporization occur.
Reboiler
1. Partial reboiler will be used for all distillation column

2. Operating condition before and after the reboiler is assumed to
be the same, thus only heat of condensation.
Pump
1. Pump Efficiency is 75%
Reactor
1. nout Hout - nin Hin= 0

2. Since, there is no mechanical contributed energy or other
external energy affecting the reactor. Thus, Q= H
Crystallizer
1. Total heat released is only contributed by naphthalene since t

he mole fraction of toluene is negligible.
27 | P a g e
IV.3
Mass Balance
Flash 1(FV-101)
Type
: Flash
Objective
: To separate the feed into vapour (mainly methane and ethane)
and liquid fraction (mainly water).
Pressure
: 60.4 bar
Temperature: 30.0 oC
Operating Conditi
ons
Temperature(oC)
Pressure(bar)
Compon
ents
Inlet str
eam
S-02
S-03
S-04
30.0
60.7
30.0
60.4
30.0
60.4
Outlet streams
Mass balance
mF(kmo
l/h)
0.00
0.00
0.00
0.00
0.00
0.00
0.00
2.13
In(S-02
)
MF(kg/
h)
24.12
110.80
12180.59
4451.36
2341.57
1235.72
460.76
67.31
Out(S-0
3)
MF(kg/
h)
24.11
110.80
12180.59
4451.36
2341.54
1235.71
460.76
28.90
Out(S-0
4)
MF(kg/
h)
0.00
0.00
0.00
0.00
0.03
0.01
0.00
38.41
2.13
20872.21
20833.77
38.44
S-02
S-03
S-04
CO2
N2
CH4
C2H6
C3H8
C4H10
C5H12
H2O
mF(kmol
/h)
0.55
3.96
759.27
148.04
53.10
21.26
6.39
3.74
mF(kmo
l/h)
0.55
3.96
759.27
148.04
53.10
21.26
6.39
1.60
Total
996.30
994.17
20872.21
*Refer to AI.8 page 18-19 in appendix for calculation.
28|P a g e
Dehydrator (DH-101 and DH-102)
Type
: Adsorption column
Objective
: To remove the remaining water vapour in the feed
Adsorbent
: Silica gel
Pressure
: 60.1 bar
Temperature: 30.0oC
Operating Conditi
ons
Temperature(oC)
Pressure(bar)
Compone
nts
CO2
N2
CH4
C2H6
C3H8
C4H10
C5H12
H2O
Total
Inlet str
eam
S-03
S-06
S-07
30.0
60.4
30.0
60.1
30.0
60.1
Outlet streams
S-03
S-06
mF(kmo
l/h)
mF(kmo
l/h)
0.55
3.96
759.27
148.04
53.10
21.26
6.39
1.60
994.17
0.55
3.96
759.27
148.04
53.10
21.26
6.39
0.00
992.56
S-07
mF(k
mol/h
)
0.00
0.00
0.00
0.00
0.00
0.00
0.00
1.60
1.60
Mass balance
In(S-03)
Out(S-06)
Out(S-07
)
MF(kg/h)
MF(kg/h)
MF(kg/h)
24.11
110.80
12180.59
4451.36
2341.54
1235.71
460.76
28.90
20833.77
24.11
0.00
110.80
0.00
12180.59
0.00
4451.36
0.00
2341.54
0.00
1235.71
0.00
460.76
0.00
0.00
28.90
20804.87
28.90
20833.77
29 | P a g e
Membrane separator (MR-101)
Type
Objective
Pressure
: Membrane separator
: To separate methane and ethane out in the feed.
: 15.4 bar
Temperature: 30.0oC
Operating Conditi
ons
Temperature(oC)
Pressure(bar)
Compon
ents
Inlet strea
m
S-09
S-20
S-10
30.0
15.4
30.0
5.1
30.0
15.4
Outlet streams
Mass balance
mF(kmo
l/h)
0.00
0.00
0.00
0.00
46.73
19.77
6.07
In(S-09
)
MF(kg/
h)
24.11
110.80
12180.59
4451.36
2341.54
1235.71
460.76
Out(S-2
0)
MF(kg/
h)
24.11
110.80
12180.59
4451.36
280.98
86.50
23.04
72.57
20804.87
17157.38
S-09
S-20
S-10
CO2
N2
CH4
C2H6
C3H8
C4H10
C5H12
mF(kmol/
h)
0.55
3.96
759.27
148.04
53.10
21.26
6.39
mF(km
ol/h)
0.55
3.96
759.27
148.04
6.37
1.49
0.32
Total
992.56
919.99
Out(S-10)
MF(kg/h)
0.00
0.00
0.00
0.00
2060.55
1149.21
437.72
3647.48
20804.87
30 | P a g e
Distillation Column 1 (DC-101)
Type
Objective
Pressure
: Distillation column
: To separate propane from butane and pentane
: 15.0 bar
Operating Conditions
Temperature(oC)
Pressure(bar)
Components
C3H8
C4H10
C5H12
Total
S-11
78.8
15.2
Inlet stream
S-11
S-14
43.9
15.0
Outlet streams
S-14
S-19
S-19
104.9
15.4
In(S-11)
Out(S-14)
Mass balance
Out(S-19)
mF(kmol/h)
mF(kmol/h)
mF(kmol/h)
MF(kg/h)
MF(kg/h)
MF(kg/h)
46.73
19.77
6.07
72.57
46.26
0.47
0
46.73
0.47
19.30
6.07
25.84
2060.59
1149.08
437.94
3647.61
2039.86
27.32
0.00
2067.18
20.73
1121.76
437.94
1580.43
3647.61
31 | P a g e
MEA Scrubber (SC-101) (4)

Note:
(4)
indicates to refer to the diagram below:
Type
Objective
Pressure
: Scrubber
: To remove CO2 in feed gas using MEA as solvent
: 3.8 bar
Temperature(oC)
Pressure(bar)
S-22
38.0
4.1
S-36
38.0
4.1
S-39
38.0
3.8
S-23
38.0
3.8
32 | P a g e
Component
Inlet stream
S-22
S-36
mF
mF
(kmol/h)
(kmol/h)
0.55
0.05
3.96
0.00
759.27
0.00
148.04
0.00
6.37
0.00
1.49
0.00
0.32
0.00
0.00
6129.67
919.99
6129.72
CO2
N2
CH4
C2H6
C3H8
C4H10
C5H12
30%MEA sol.
Total
Outlet streams
S-39
S-23
mF
mF
(kmol/h)
(kmol/h)
0.05
0.49
3.96
0.00
759.27
0.00
148.04
0.00
6.37
0.00
1.49
0.00
0.32
0.00
0.00
6129.67
919.50
6130.16
Mass balance
In(S-22)
In(S-36)
Out(S-39)
Out(S-23)
MF
MF
MF
MF
(kg/h)
(kg/h)
(kg/h)
(kg/h)
24.11
2.2
2.41
21.56
110.80
0.00
110.80
0.00
12180.59
0.00
12180.59
0.00
4451.36
0.00
4451.36
0.00
280.98
0.00
280.98
0.00
86.50
0.00
86.50
0.00
23.04
0.00
23.04
0.00
0.00
189406.8
0.00
189406.8
17157.4
189409.0
17135.7
189428.4
206564.1
206564.1
MEA Solvent Regenerator (ST-101) (4)

Type
Objective
Pressure
: Stripper
: To regenerate MEA by removing CO2 from the solvent.
: 2.5 bar
Temperature(oC)
Pressure(bar)
Components
CO2
MEA
Total
Inlet stream
S-25
S-30
mF(kmol/h)
mF(kmol/h)
0.49
0.44
6129.67
0.03
6130.16
0.47
S-25
269.0
4.0
Outlet streams
S-33
mF(kmol/h)
0.05
6129.64
6129.69
S-30
20.0
2.5
In(S-25)
MF(kg/h)
21.56
189406.8
189428.40
S-33
269.0
4.0
Out(S-30)
MF(kg/h)
19.36
0.88
20.24
Mass balance
Out(S-33)
MF(kg/h)
2.20
6128.76
6130.96
189428.40
33 | P a g e
Mixing Point
Objective
Pressure
: To combine feed and recycle stream before entering reactor 1.

: 3.6 bar
Temperature(oC)
Pressure(bar)
Components
CO2
N2
CH4
C2H6
C3H8
C4H10
C5H12
C6H6
C10H8
C7H8
H2
C2H4
C3H6
Total
Inlet stream
S-40
mF(kmol/h)
0.05
3.96
759.27
148.04
6.37
1.49
0.32
0.00
0.00
0.00
0.00
0.00
0.00
919.50
S-40
700.0
3.6
Inlet stream
S-88
mF(kmol/h)
5.81
41.35
5218.70
72.92
61.89
10.13
1.31
38.41
0.01
0.62
82.96
11.73
0.06
5545.91
Outlet streams
S-41
mF(kmol/h)
5.86
45.30
5977.97
220.96
68.26
11.62
1.63
38.41
0.01
0.62
82.55
11.67
0.06
6464.95
S-88
700.0
3.6
S-41
700.0
3.6
Mass balance
In(S-40)
In(S-88)
Out(S-41)
MF(kg/h)
MF(kg/h)
MF(kg/h)
2.41
255.50
257.91
110.80
1158.33
1269.13
12180.59
83721.06
95901.64
4451.36
2192.76
6644.12
280.98
2728.94
3009.93
86.50
588.99
675.49
23.04
94.53
117.57
0.00
3000.44
3000.44
0.00
1.43
1.43
0.00
56.97
56.97
0.00
166.42
166.42
0.00
327.51
327.51
0.00
2.73
0.00
17135.65
94295.61
111428.56
111431.26 (0.002% error)
*Refer to AI.8 page 22-23 in appendix for mixing point calculation.
34 | P a g e
Reactor 1 (RX-101)
Type
Objective
Catalyst
Pressure
:
:
:
:
Isothermal packed bed reactor

To convert methane and ethane to benzene
Mo/HZSM-5
3.6 bar
Temperature : 700.0 oC
Temperature(oC)
Pressure(bar)
Components
CO2
N2
CH4
C2H6
C3H8
C4H10
C5H12
C6H6
C10H8
C7H8
H2
C2H4
C3H6
C
Total
Inlet stream
S-41
mF(kmol/h)
5.86
45.30
5977.97
220.96
68.26
11.62
1.63
38.41
0.01
0.62
82.55
11.67
0.06
0.00
6464.95
S-41
700.0
3.6
Outlet stream
S-42
mF(kmol/h)
6.34
45.03
6024.19
173.84
69.07
11.89
1.76
68.10
7.79
2.31
204.16
1.49
0.07
0.00
6616.05
S-42
700.0
1.8
Mass balance
In(S-41)
Out(S-42)
MF(kg/h)
MF(kg/h)
257.91
278.92
1269.13
1261.57
95901.64
96643.11
6644.12
5227.10
3009.93
3045.54
675.49
691.07
117.57
126.99
3000.44
5319.57
1.43
999.05
56.97
212.53
166.42
411.56
327.51
41.94
0.00
3.05
0.00
0.00
111428.56
114261.99
2.47% error
35 | P a g e
Reactor 2 (RX-102)
Type
Objective
Catalyst
Pressure
:
:
:
:
Isothermal packed bed reactor

To convert methane and ethane to benzene
Mo2C/ZSM-5
1.8 bar
Temperature: 700.0oC
Temperature(oC)
Pressure(bar)
Components
CO2
N2
CH4
C2H6
C3H8
C4H10
C5H12
C6H6
C10H8
C7H8
H2
C2H4
C3H6
C
Total
Inlet stream
S-42
mF(kmol/h)
6.34
45.03
6024.19
173.84
69.07
11.89
1.76
68.10
7.79
2.31
204.16
1.49
0.07
0.00
6616.05
S-42
700.0
1.8
Outlet stream
S-44
mF(kmol/h)
6.34
45.03
5677.51
79.61
69.07
11.89
1.76
148.46
7.79
5.98
901.83
12.79
0.07
4.67
6972.82
S-44
700.0
1.3
Mass balance
In(S-42)
Out(S-44)
MF(kg/h)
MF(kg/h)
278.92
278.92
1261.57
1261.57
96643.11
91081.53
5227.10
2393.77
3045.54
3045.54
691.07
691.07
126.99
126.99
5319.57
11596.76
999.05
999.05
212.53
550.81
411.56
1817.99
41.94
358.81
3.05
3.05
0.00
56.12
114261.99
114261.99
*Refer to AI.8 page 20-21 in appendix for reactor 2 calculation. 36 | P a g e
Flash 2 (FV-102)
Type
Objective
Pressure
: Flash
: To separate the products from unreacted feed gas.
: 19.7 bar
Temperature: 20.0oC
Temperature(oC)
Pressure(bar)
Components
CO2
N2
CH4
C2H6
C3H8
C4H10
C5H12
C6H6
C10H8
C7H8
H2
C2H4
C3H6
Total
Inlet stream
S-51
mF(kmol/h)
6.34
45.03
5677.51
79.61
69.07
11.89
1.76
148.46
7.79
5.98
901.83
12.79
0.07
6968.15
S-51
20.0
20.0
Outlet streams
S-52
S-53
mF(kmol/h)
mF(kmol/h)
6.31
0.03
45.03
0.01
5672.50
5.01
79.27
0.34
67.27
1.80
11.01
0.88
1.42
0.34
41.75
106.71
0.01
7.78
0.67
5.31
901.78
0.06
12.75
0.05
0.07
0.00
6839.84
128.30
*Refer to AI.8 page 20 in the appendix for flash 2 calculation.
S-52
20.0
19.7
In(S-51)
MF(kg/h)
278.92
1261.57
91081.53
2393.77
3045.54
691.07
126.99
11596.76
999.05
550.81
1817.99
358.81
3.05
114205.86
S-53
20.0
19.7
Mass balance
Out(S-52)
Out(S-53)
MF(kg/h)
MF(kg/h)
277.72
1.21
1261.31
0.26
91001.15
80.38
2383.43
10.34
2966.24
79.30
640.20
50.86
102.75
24.23
3261.35
8335.41
1.55
997.50
61.93
488.88
1817.87
0.12
357.55
1.26
2.97
0.08
104136.03
10069.82
114205.86
37 | P a g e
Pressure Swing Adsorption Unit (PS-101-PS-104)
Type
Objective
Adsorbent
Pressure
:
:
:
:
Adsorption Column
To remove hydrogen from unreacted feed
Alumina, activated carbon
19.7 bar
Temperature(oC)
Pressure(bar)
Component
CO2
N2
CH4
C2H6
C3H8
C4H10
C5H12
C6H6
C10H8
C7H8
H2
C2H4
C3H6
Total
Inlet stream
S-64
mF(kmol/h)
6.31
45.03
5672.50
79.27
67.27
11.01
1.42
41.75
0.01
0.67
901.78
12.75
0.07
6839.84
S-52
20.0
19.7
Outlet streams
S-66
S-65
mF(kmol/h)
mF(kmol/h)
6.31
0.00
44.94
0.08
5672.50
0.00
79.27
0.00
67.27
0.00
11.01
0.00
1.42
0.00
41.75
0.00
0.01
0.00
0.67
0.00
90.18
811.60
12.75
0.00
0.07
0.00
6028.16
811.68
S-85
40.0
3.8
In(S-64)
MF(kg/h)
277.72
1261.31
91001.15
2383.43
2966.24
640.20
102.75
3261.35
1.55
61.93
1817.87
357.55
2.97
104136.03
S-86
20.0
18.0
Mass balance
Out(S-66)
Out(S-65)
MF(kg/h)
MF(kg/h)
277.72
0.00
1259.04
2.27
91001.15
0.00
2383.43
0.00
2966.24
0.00
640.20
0.00
102.75
0.00
3261.35
0.00
1.55
0.00
61.93
0.00
181.79
1636.09
357.55
0.00
2.97
0.00
102497.67
1638.36
104136.03
38 | P a g e
Purge
Purge ratio: 8.0%

Temperature(oC)
Pressure(bar)
Components
CO2
N2
CH4
C2H6
C3H8
C4H10
C5H12
C6H6
C10H8
C7H8
H2
C2H4
C3H6
Total
Inlet stream
S-85
mF(kmol/h)
6.31
44.94
5672.50
79.27
67.27
11.01
1.42
41.75
0.01
0.67
90.18
12.75
0.07
6028.16
Outlet stream
S-88
mF(kmol/h)
5.81
41.35
5218.70
72.92
61.89
10.13
1.31
38.41
0.01
0.62
82.55
11.67
0.06
5545.45
S-85
40.0
3.8
Outlet stream
S-87
mF(kmol/h)
0.50
3.60
453.80
6.34
5.38
0.88
0.11
3.34
0.00
0.05
7.18
1.02
0.01
482.21
S-88
40.0
3.8
In(S-85)
MF(kg/h)
277.72
1259.04
91001.15
2383.43
2966.24
640.20
102.75
3261.35
1.55
61.93
181.79
357.55
2.97
102497.67
Please refer to AI.8 page 22-23 in appendix for calculation.
S-87
40.0
3.8
Mass balance
Out(S-88)
Out(S-87)
MF(kg/h)
MF(kg/h)
255.50
22.22
1158.33
100.72
83721.06
7280.09
2192.76
190.67
2728.94
237.30
588.99
51.22
94.53
8.22
3000.44
260.91
1.43
0.12
56.97
4.95
166.42
14.47
327.51
28.48
2.73
0.24
94295.61
8199.62
102495.23 (0.002% error)
39 | P a g e
Type
Objective
Pressure
: To remove light hydrocarbons from products in order to reach the industrial grade purity
: 3.2 bar
Temperature(oC)
Pressure(bar)
Components
CO2
N2
CH4
C2H6
C3H8
C4H10
C5H12
C6H6
C10H8
C7H8
H2
C2H4
C3H6
Total
Inlet stream
S-55
mF(kmol/h)
0.03
0.01
5.01
0.34
1.80
0.88
0.34
106.71
7.78
5.31
0.06
0.05
0.00
128.30
S-55
97.0
3.5
Outlet streams
S-62
S-63
mF(kmol/h)
mF(kmol/h)
0.03
0.00
0.01
0.00
5.01
0.00
0.34
0.00
1.80
0.00
0.87
0.00
0.32
0.01
1.07
105.64
0.00
7.78
0.00
5.31
0.06
0.00
0.05
0.00
0.00
0.00
9.56
118.75
S-62
48.5
3.2
In(S-55)
MF(kg/h)
1.19
0.25
80.37
10.34
79.28
50.86
24.24
8335.39
997.55
488.89
0.12
1.26
0.08
10069.83
S-63
137.7
4.2
Mass balance
Out(S-62)
MF(kg/h)
1.19
0.25
80.37
10.34
79.28
50.80
23.38
83.35
0.00
0.09
0.12
1.26
0.08
330.52
Out(S-63)
MF(kg/h)
0.00
0.00
0.00
0.00
0.00
0.06
0.87
8252.04
997.55
488.79
0.00
0.00
0.00
9739.31
10069.83
40 | P a g e
Type
Objective
Pressure
: To produce benzene with a purity greater than 99 wt%.
: 1.8 bar
Operating Conditi
ons
Temperature(oC)
Pressure(bar)
Compon
ents
C4H10
C5H12
C6H6
C10H8
C7H8
Total
Inlet
stream
S-64
S-71
S-73
113.0
2.2
97.4
1.8
164.2
2.3
Outlet streams
S-64
S-71
S-73
mF(kmol
/h)
0.00
0.01
105.64
7.78
5.31
118.75
mF(kmo
l/h)
0.00
0.01
104.06
0.00
0.31
104.39
mF(kmo
l/h)
0.00
0.00
1.58
7.78
4.99
14.36
Mass balance
In(S64)
MF(kg/
h)
0.06
0.86
8252.06
997.50
488.81
9739.28
Out(S71)
MF(kg/
h)
0.06
0.86
8128.28
0.00
28.85
8158.05
Out(S73)
MF(kg/
h)
0.00
0.00
123.78
997.50
459.96
1581.23
9739.28
41 | P a g e

Type
Objective
Pressure
: To separate toluene from naphthalene.
: 2.0 bar
Operating Condition
s
Temperature(oC)
Pressure(bar)
Compone
nts
C6H6
C10H8
C7H8
Total
Inlet
stream
S-73
mF(kmol/
h)
1.58
7.78
4.99
14.36
S-73
S-83
S-79
164.2
2.3
137.8
2.0
257.6
2.5
Outlet streams
S-83
mF(kmol
/h)
1.58
0.08
4.91
6.58
S-79
mF(kmol
/h)
0.00
7.70
0.08
7.78
Mass balance
In(S-73)
MF(kg/h
)
123.78
997.50
459.96
1581.23
Out(S-83)
Out(S-79)
MF(kg/h)
MF(kg/h)
123.78
9.97
452.79
586.54
0.00
987.52
7.17
994.69
1581.23
Crystallizer (CR-101)
Type
Objective
Pressure
: Crystallizer
: To crystallize naphthalene.
: 1.5 bar
Temperature: 35.0oC
Temperature(oC)
Pressure(bar)
Components
C10H8
C7H8
Total
Inlet stream
S-91
mF(kmol/h)
7.70
0.08
7.78
S-91
90.0
2.2
Outlet streams
S-92
mF(kmol/h)
7.70
0.08
7.78
S-92
35.0
1.5
Mass balance
In(S-91)
Out(S-92)
MF(kg/h)
MF(kg/h)
987.52
987.52
7.17
7.17
994.69
994.69
42 | P a g e

IV.4 ENERGY BALANCE BEFORE HEAT INTEGRATION
Heat Exchanger
Equipment
HE-101
HE-102
HE-103
HE-104
HE-105
HE-106
HE-107
HE-108
HE-109
HE-110
HE-111
HE-112
HE-113
HE-114
HE-115
HE-116
Inlet Condition
Pressure Temperature
(bar)
(C)
61
48.9
60.1
30.0
4.3
28.0
15.4
30.0
4.3
38.5
4.0
269.0
3.8
38.0
1.3
700.0
3.0
152.0
7.5
167.0
20.2
190
19.7
20.0
3.8
40.0
1.8
97.4
1.5
90.3
2.5
258
Outlet Condition
Pressure Temperature
(bar)
(C)
60.7
30.0
59.9
87.0
4.1
38.0
15.2
78.8
4
269.0
3.7
39.0
3.6
700.0
1.1
43.0
2.8
58.0
7.3
76.0
20.0
20.0
19.4
113.0
3.6
700.0
1.5
30.0
1.3
30.0
2.2
90
Energy Rele
ased/
Needed(KW)
-412.12
699.00
100.36
361.30
10.37
-10.43
10330.73
-70270.32
-7398.34
-7908.23
-14418.90
440.30
56937.11
-263.21
-30.51
-88.35
Expander
Equipment
EX-101
Inlet Condition
Pressure ( Temperature
bar)
(C)
59.9
87.0
Outlet Condition
Energy R
Pressure (b Temperature eleased (
KW)
ar)
(C)
15.2
30.0
-694.63
Inlet Condition
bar)
(C)
1.1
43.0
2.8
58.0
7.3
76.0
Outlet Condition
Energy N
Pressure (b Temperature eeded (K
W)
ar)
(C)
3.0
152.0
7450.74
7.5
167.0
7356.50
20.2
190.0
8024.97
Compressor
Equipment
C-101
C-102
C-103
Reactor
Equipment
RX-101
RX-102
Inlet Condition
Pressure
Temperature
(bar)
(C)
3.6
700
1.8
700
Outlet Condition
bar)
(C)
1.8
700
1.3
700
Energy
Needed
(KW)
1676.65
10914.40
43 | P a g e

Reboiler and Condenser
Equipment
CD-101
RB-101
CD-102
RB-102
CD-103
RB-103
CD-104
RB-104
CD-105
RB-105
Inlet Condition
bar)
(C)
15.0
43.9
15.4
104.9
2.5
20.0
4.0
269.0
3.2
48.5
4.2
137.7
1.8
97.4
2.3
164.2
2.0
139.6
2.5
258.0
Outlet Condition
Pressure (b Temperature
ar)
(C)
15.0
43.9
15.4
104.9
2.5
20.0
4.0
269.0
3.2
48.5
4.2
137.7
1.8
97.4
2.3
164.2
2.0
139.6
2.5
258.0
Energy N
eeded (K
W)
Inlet Condition
bar)
(C)
15.0
43.9
3.8
38
1
32
2.5
20
3.4
37
3.2
48.5
1.8
97.4
1.5
90.3
Outlet Condition
Energy N
Pressure (b Temperature eeded (K
W)
ar)
(C)
15.4
44.4
0.2900
4.3
38.5
0.0020
4.4
38
0.0002
4
21.5
0.0024
4.4
38
0.0016
4.1
49.4
0.3500
2.2
97.9
0.3034
1.9
90.8
0.0025
-356.30
370.70
-2.78
14.20
-376.48
354.34
-848.59
1347.20
-11.95
87.62
Pump
Equipment
PM-101
PM-102
PM-103
PM-104
PM-105
PM-106
PM-107
PM-108
Crystallizer
Equipment
CR-101
Inlet Condition
P(bar)
T(C)
2.2
90.0
Outlet Condition
P(bar)
T(C)
1.5
35.0
E(KW)
Released
-54.76
44 | P a g e
IV.5 Comparison: Manual Mass Balance and Simulation

Stream
Manual Calculation (kg/h) Simulation (kg/h) % Error
S-01 to S-02
20872.21
20872.64
0.002
S-03
20833.77
20834.12
0.002
S-04 to S-05
38.44
38.52
0.204
S-06, S-08
to S-09
20804.87
20805.22
0.002
S-07
28.90
28.90
0.014
S-10 to S-11
3647.48
3647.54
0.001
S-14
2067.14
2067.24
0.005
S-19
1580.46
1580.30
0.011
S-20 to S-22
17157.38
17157.69
0.002
S-23 to S-25
74.35
7069.78
9408.787
S-30
22.36
161.65
622.898
S-33 to S-35
52.77
6908.13 12990.663
S-36
54.35
7068.92 12906.306
S-37 to S-38
0.88
2.23
155.314
S-39 to S-40
17135.68
17156.83
0.123
S-41
111428.56
95930.11
13.909
S-42
114261.99
95930.08
16.044
S-44 to S-51
114261.98
95929.7723
16.044
S-52
104136.03
87336.01
16.133
S-53 to S-55
10069.82
8566.63
14.928
S-62
330.54
257.06
22.229
S-63 to S-64
9739.28
8309.57
14.680
S-71 to S-72
8158.05
6932.20
15.026
S-73
1581.23
1377.36
12.893
S-79 to S-81
994.69
994.48
0.021
S-82
994.69
994.48
0.021
S-83 to S-84
586.54
482.88
17.674
S-85
102497.67
85571.41
16.514
S-86
1638.36
1764.61
7.706
S-87
8199.62
6845.71
16.512
S-88 to S-89
94295.61
78773.28
16.461
45 | P a g e
ENERGY COMPARISON BETWEEN MANUAL AND SIMULATION

HEAT EXCHANGER
HE-101
HE-102
HE-103
HE-104
HE-105
HE-106
HE-107
HE-108
HE-109
HE-110
HE-111
HE-112
HE-113
HE-114
HE-115
HE-116
SIMULATION (KW)
310.80
858.30
87.67
413.90
2144.00
2138.00
10350.00
65280.00
6865.00
6968.00
13760.00
352.10
53260.00
271.40
24.49
89.38
MANUAL (KW)
412.12
699.00
100.36
361.30
10.37
10.63
10330.73
70270.32
7398.34
7908.23
14418.90
440.30
57972.33
263.21
30.51
88.35
DIFFERENCE %
24.58
22.33
12.64
14.56
20575.02
20012.89
0.19
17.19
15.70
20.02
15.94
11.56
19.72
3.11
19.73
1.16
REACTOR
RX-101
RX-102
SIMULATION (KW)
2221.00
12080.00
MANUAL (KW)
1676.65
10914.40
DIFFERENCE %
32.47
10.68
EXPANDER/COMPRESSOR
EX-101
C-101
C-102
C-103
SIMULATION
(KW)
601.90
7199.00
7371.00
7158.00
MANUAL (KW)
DIFFERENCE %
694.63
7450.74
7356.50
8024.97
13.34
3.39
0.20
10.80
CONDENSER
CD-101
CD-103
CD-104
CD-105
SIMULATION (KW)
440.5
448.5
1734.00
73.78
MANUAL (KW)
356.30
376.48
848.59
11.95
DIFFERENCE %
23.63
19.13
104.34
517.41
REBOILER
RB-101
RB-103
RB-104
RB-105
SIMULATION (KW)
329.20
638.10
1648.00
111.40
MANUAL (KW)
370.70
354.34
1347.20
87.62
DIFFERENCE %
11.20
80.08
22.33
27.14
46 | P a g e
Justification For Mass Balance

Fluid packages used in HYSYS simulation are Peng-Robinson (PR) with NonRandom-Two-Liquid (NRTL) and PR. PR is chosen as Equation of State (EOS) in
this simulation as it is suitable for hydrocarbon systems and is widely used for
petrochemical application. Condition of the plant also fulfil the requirement for
the usage of PR (temperature > -271oC and P< 1000 bar). NRTL is used as
activity model along with PR in the first part of plant (FV-101 and DH-102, DH103) as water which is of polar nature is present. After the dehydrator unit, only
PR is used in the simulation as water is assumed to be fully removed.
Membrane (MR-101), absorber (SC-101) and pressure swing adsorption unit
(PSA) are simulated as component splitters whereas short-cut distillation
columns are used for the simulation of distillation columns (DC-101, DC-102,
DC-103 and DC-104) and stripper (ST-101). First reactor (RX-101) is simulated
as a plug flow reactor as there is no packed bed reactor available in HYSYS while
conversion reactor is used for the second reactor (RX-102).
Significant differences are observed between the calculated and simulated result
for streams involving MEA solvent (S-23, S-30, S-33, S-36 and S-37). This is
because PR is not suitable to be used for simulation involving MEA. Amines
model should be used instead for simulation involving MEA or other amines.
Moreover, differences between calculated and simulated results are seen after
reactor 1 (S-42). This is because the actual kinetic values used in the manual
calculation uses kinetics that are in terms of weight (PBR form) which is more
accurate whereas the HYSYS simulation cannot be simulated accurately since it
requires in terms of volume (PFR form) which is not provided by literature. The
difference in values are accumulated and brought forward to the subsequent
streams, thus causing the difference between calculated and simulated result in
the following streams (after reactor 1). So, manual calculation for mass balance
is chosen for the following sections.
Justification For Energy Balance

For energy balance, the difference between manual and simulation is relatively
big, especially for HE-105, HE-107, CD-104 and CD-105. For HE-105 and HE107, the fluid package used is not suitable for simulation involving MEA solvent,
causing large deviation in flowrate of the streams. As a result, large difference
between calculated and simulated energy balance is observed. Deviation of
manual and simulated energy balance is expected since manual mass flowrates
differ from the simulated flowrates. The assumption of ideal system in doing
manual calculation for energy balance also contributed to the error. However, the
difference in energy balance for the rest of equipment is still less than 100%. In
conclusion, manual calculation of energy balance is chosen for the following
sections as manual mass balance is selected.
47 | P a g e
Section V. Energy Recovery and Utilities

MODULE CODE
GROUP
GA SUPERVISOR
ACADEMIC SUPERVISOR
DATE OF SUBMISSION
AUTHORS
STUDENT ID
Group member:
NAME
H83DPX
4
Prof. Dominic Foo
Prof. Dominic Foo
Mr. Rafil
18th April 2016
FIDELIA PRASETYA
011494
STUDENT ID
013802
Chan Joel Kai Chin
011032
Kim Tae Yeon

Soh Yi Shin Elaine
013461
013332
PROGRAMME
MEng Chemical with

Selangor, Malaysia
E | Page

V.1 Introduction
One of the most common problems that can be found in industrial plants is
excessive energy consumption. Heat exchanger network can be used to reduce
the energy consumption by using hot stream to heat the cold stream and using
cold streams to cool down the hot streams. It is also possible to reduce the
number of equipment that need to be used thus it will decrease the fixed cost as
well. In this HEN design, no loops have found. Hence, the number of equipment
cannot be reduced. However, the energy in the whole plant can be saved by
approximately 69%
Table V.1.1: Comparison of Energy Needed Before and after Heat Integration
Heat Exchanger Heat Duty- Before Heat Exchanger Heat duty- After
(Before)
(kW)
(After)
(kW)
HE-101
412.12
HE-101
412.12
HE-102
699.00
HE-102
699.00
HE-103
100.36
HE-103
100.36
HE-104
361.30
HE-104
361.30
HE-105
10.37
HE-105
10.37
HE-106
10.63
HE-106
10.63
HE-107
10330.73
F-101
8114.77
HE-108
70270.32
HE-108
14195.90
HE-109
7398.34
HE-109
7398.34
HE-110
7908.23
HE-110
7908.23
HE-111
14418.90
HE-111
8990.87
HE-112
440.30
HE-117
2807.92
HE-113
56937.11
HE-115
88.75
HE-114
263.21
F-102
862.68
HE-115
30.51
HE-116
30.51
HE-116
88.35
TOTAL
52395.90
TOTAL
169679.78
*before heat integration, the naming of HE follow the PFD before Heat Integration
*after heat integration, the naming of HE follow the PFD after Heat Integration
V.2 Pinch Analysis and Heat Exchanger Network Design
To obtain an optimal heat exchanger network using Pinch Analysis, some steps
must be followed. First of all, the minimum energy demand and minimum
number of heat exchangers need to be found. Then, the second step is consist of
heat exchanger network design and the last one is to identifying and breaking
the loop, if any
During the heat exchanger network design, the Tmin must be determined. In
this HEN design, the Tmin of 10C is used. The energy consumption is having
behaviour as function of Tmin. As the Tmin increase, the energy consumption
will also increase. However, the exchange area will decrease. Thus, Tmin of
10C is chosen
In this plant, the heat exchanger designs are divided to three sections. However,
HE-101 up to HE-106 is not involved in the heat integration due to very less
amount of energy that can be saved. The HEN Design has been separated into 3
parts. This is due the pinch analysis rule. Some of the combination of the heat
exchangers will violate the rules such as Tmin of 10C is not reached and it will
48 | P a g e

make the system is not feasible.
The first part of this HEN design involves two heat exchangers which are HE-107
and HE-111. Based on the problem table algorithm, the pinch point occurred at
185 C . Although there is no heat pockets in the Grand Composite Diagram
(Refer to Figure V.2.2), the energy consumption for cold and hot stream still can
be reduced by 17.90%
Table V.2.1: Problem Table Algorithm Part 1
Grand Composite Curve Part 1

800
700
Temperature, C
600
500
400
300
200
100
0
0.00
2000.00 4000.00 6000.00 8000.00 10000.0012000.0014000.00
Heat Duty, kW
Figure V.2.2: Grand Composite Curve 1
The second part of this HEN design involves 4 heat exchangers which are HE108, HE-109, HE-110, and HE-113. The pinch point for this system is quite high,
which is 690C. There is no heat pocket found in the grand composite curve but
the energy consumption still can be reduced significantly by 78.69%.
49 | P a g e

800
700
Temperature, C
600
500
400
300
200
100
0
0.00
5000.00
10000.00
15000.00
20000.00
25000.00
30000.00
35000.00
Heat Duty, kW
Figure V.2.4: Grand Composite Curve 2
For part 3, the heat exchangers involve are HE-112, HE-114 and HE-116. It is
shown that there is heat pocket in the grand composite graph although this is a
threshold problem. Hence, the heat exchange process will occur here. There is
no pinch point found in the system. However, the energy still can be reduced
significantly by 88.79%.
50 | P a g e
300
Temperature, C
250
200
150
100
50
0
0.000
50.000
100.000
150.000
200.000
Heat Duty, kW
Figure V.2.6: Grand Composite Curve Part 3
V.3 Grid Diagram
After Problem Table Algorithm has been done, the next step is to draw the grid
diagram. By drawing the grid diagram, it can be shown that there will be heat
exchange occur between hot and cold stream. However, there are some rules for
exchanging the heat between hot and cold stream.
Above the pinch point, only heater is allowed and the heat capacity of hot
stream must be lower than heat capacity of cold stream. On the opposite, only
cooler is allowed for the stream below the pinch point and heat capacity of hot
stream must be greater than cold stream. The Tmin of 10C need to be
maintained throughout the system.
51 | P a g e
Figure V.3.1: Grid Diagram for the HEN Design

Based on the figure above, both part 1 and part 2 have pinch point. However
, no pinch point found in the part 3, it means that this is a threshold proble
m. In this case, the system only need hot utility. For all the 3 parts, no loop
has been found. Hence, no heat exchanger can be reduced. Based on pinch
analysis rule, the minimum number of unit needed for all the sections are cor
rect.
Nunits =(S-1)ABOVE PINCH +(S-1)BELOW PINCH
Part 1
Nunits = 3 , which means match with the rule (1 heater, 1 cooler, and 1 heat
exchanger)
Part 2
Nunits = 5, which means match with the rule (1 heater, 1 heat exchanger, and
3 cooler)
Part 3
Since there is no streams below the pinch, thus (S-1)BELOW PINCH is ignored.
Nunits = 3, which means match with the rule (1 heater, 1 heat exchanger, an
d 1 cooler) although did not have any pinch point. (Smith, 2005).
52 | P a g e
V.4 PFD AFTER HEAT INTEGRATION
53 | P a g e
V.5 UTILITY BALANCE and ENERGY AUDIT (Follow the UPDATED PFD
AFTER HEAT INTEGRATION)
Table V.5.1: Cooler Duty after Heat Integration
Heat Exchanger
Utilities
Heat Duty
Mass Flow Rate
(kW)
(Kg/s)
HE-101
Chilled Water
412.12
5.45
HE-106
Cooling Water
10.63
0.09
HE-108
Cooling Water
14195.90
125.18
HE-109
Cooling Water
7398.34
65.24
HE-110
Cooling Water
7908.23
69.74
HE-111
Cooling Water
8990.87
82.50
HE-116
Chilled Water
30.51
0.40
HE-117
Chilled Water
2807.92
37.14
CD-101
Chilled Water
356.30
4.71
CD-102
Chilled Water
2.78
0.04
CD-103
Chilled Water
376.48
4.97
CD-104
Cooling water
848.59
7.48
CD-105
Cooling water
11.95
0.11
The utilities use for the cooler is either cooling or chilled water. To calculate the
mass flow rate needed, the heat capacity for water has been assumed to be
constant at 4.2 kJ/Kmol K. Total water needed to cool down the stream after
heat integration is 403.05 kg/s, previously the water needed to cool down the
stream is 1036.45 kg/s. It has been reduced significantly by 61.00%.
Table V.5.2: Heater and Furnace after Heat Integration
Heat Exchanger
Utilities
Heat Duty
Mass Flow Rate
(kW)
(Kg/s)
HE-102
Steam
699.00
0.33
HE-103
Steam
100.36
0.05
HE-104
Steam
361.30
0.17
HE-105
Hot oil
10.37
0.13
HE-115
Steam
88.75
0.05
RB-101
Steam
370.70
0.20
RB-102
Hot oil
14.20
0.17
RB-103
Steam
354.34
0.19
RB-104
Steam
1347.20
0.71
RB-105
Hot oil
87.62
1.06
F-101
Natural Gas
8114.77
0.16
F-102
Natural Gas
862.68
0.02
Steam cannot be used as utility for all of the heat exchanger due to the
temperature limitation. Hence, several utilities are chosen (refer to appendix
AIII.V.1). Before heat integration, the total steam needed is 1.87 kg/s. After
heat integration, the total mass of steam can be reduced by approximately by
9.00%.
For HE-105, RB-103, and RB-104, hot oil is used due to high temperature
54 | P a g e
needed to heat it up the stream. Assuming the hot oil utility supplied (will be
preheated) at 315C and come out at 279C and constant heat capacity of hot
oil is 2.3 kJ/Kmol K. The amount of hot oil needed for before and after heat
integration are the same.
F-101 and F-102 are needed in order to heat it up the streams up to 700C.
Hence, natural gas is chosen for this equipment. Before heat integration, the
amount of natural needed is 1.29 kg/s. After heat integration, the amount of
natural gas can be reduced by 86.00%
Reactor
RX-101
RX-102
Table V.5.3: Reactor

Utilities
Fuel oil from DC101
Fuel oil from DC101
Total
Compressor
C-101
C-102
C-103
Table V.5.4: Compressor

Utilities
Electricity
Electricity
Electricity
Total
Table V.5.5: Pump
Utilities
Electricity
Electricity
Electricity
Electricity
Electricity
Electricity
Electricity
Electricity
Pump
P-101
P-102
P-103
P-104
P-105
P-106
P-107
P-108
Total
Heat Duty (kW)

1676.65
10914.40
12591.05
Heat Duty (kW)

7450.74
7356.50
8024.97
22832.21
Heat Duty (kW)

0.2900
0.0020
0.0002
0.0024
0.0016
0.3500
0.3034
0.0025
0.9521
V.6 Cost of the Utility

Utility
Water
Electricity
Hot oil
Natural gas
Price (USD)
0.00041 per kg
0.14 per kWh
3.83 per kg
0.14 per kg
By doing heat integration, the cost of utility can be reduced especially for water
and natural gas consumption. The cost of the utility needed will be shown in the
economic section. There are two turbines in our plant which is TB-101 and
another one comes from the steam generation system. Electricity that can be
generated from the turbine will be used to supply to the building. Hence,
electricity cost can be reduced.
55 | P a g e
V.7 Steam Distribution

For steam distribution, it has been divided into three different pressure which
are low pressure, medium pressure, and high pressure steam.
Table V.7.1: Three Different Pressures for Steam
Steam Pressure (bar)
Evaporation energy (k
Temperature (C)
J/Kg)
Low (3)
133.50
2164.00
Medium (20)
212.40
1890.00
High (40)
250.30
1714.00
Steam is required to heat it up the stream. However, steam itself has
temperature limitation. Hence, not all the heater and reboiler are able to use
steam.
V.7.1 Steam Generation System
Figure V.7.1.1: Steam Generation System

The feed will be preheated before it goes to the boiler. The boiler itself is used
to produce medium pressure steam (20 bar). Then, turbine is used to decrease
the pressure in order to obtain low pressure steam (3 bar). Then both steam will
be condensate and return back deaerator. Deaerator is used to remove the
oxygen and other dissolved gas from the feed water before it supply to the boiler.
Amount of water needed to produce the steam is approximately 1.83 kg/s
(refers to appendix AIII.V.1 for detailed calculation).
V.8 Cooling Water System
Water will be supplied from the cooling tower at approximately 25C. When the
water is coming back to the cooling tower, the temperature is assumed to be
56 | P a g e
approximately 52C.
Figure V.8.1: Cooling Water System

Some of the feed will be loss due to blow down, evaporation, and also drift loss.
Hence, make up water will be needed. The detailed calculation of how much
water needed for makeup will be provided in appendix.
V.9 Chilled Water System
Chilled water is needed to cool down the stream that below 30C. Thus, it has
been decided to build a chilled water system. Refrigerant that has been used is
ammonia due to lower cost compare to other refrigerant. 1113.96 tons of
refrigeration needed in order to chill 52.71 kg/s of water.
Figure V.9.1: Chilled Water System
57 | P a g e
Section VI. Individual Equipment Design

MODULE CODE
GROUP
ACADEMIC SUPERVISOR
DATE OF SUBMISSION
AUTHORS
NAME
H83DPX
4
Prof. Dominic Foo
Mr. Rafil
18th April 2016
STUDENT ID
013802
Chan Joel Kai Chin
011032
Fidelia Prasetya
Kim Tae Yeon
Soh Yi Shin Elaine
011494
013461
013332
PROGRAMME
MEng Chemical with

Selangor, Malaysia
F| P a g e
A.B. Verasingham
VI.1 Equipment Design for DC-101

MODULE CODE
GROUP
ACADEMIC SUPERVISOR
EQUIPMENT DESIGN
SUPERVISOR
NAME
STUDENT ID
DATE OF SUBMISSION
AUTHORS
NAME
Fidelia Prasetya
H83DPX
4
Prof. Dominic Foo
Dr. Nishanth Chemmangattuvalappil
Mr. Rafil
ARATI BANU A/P VERASINGHAM
013802
18th April 2016
STUDENT ID
011494
Chan Joel Kai Chin
011032
Kim Tae Yeon

Soh Yi Shin Elaine
013461
013332
PROGRAMME
MEng Chemical with

Selangor, Malaysia
F| P a g e
A.B. Verasingham
DC-101 functions as a high pressure steady-state distillation column to purify
the propane from the feed into marketable propane grade namely HD-5.
Propane (LK), butane (HK) and pentane (HNK) enter the column as saturated
vapour after being separated by a membrane, MR-101 at 78.8C, 15.2 bar. The
final product is a LPG mixture with 99% of propane and 1% butane, which is
showcased in Section IV.2.32.
ASPEN HYSYS V8.4 Simulation
Figure VI.1.1: Simulation conducted using ASPEN HYSYS V8.4.

A detailed case study was conducted to provide a benchmark for a model
distillation column design. The input values were solely based on the manual
mass balance. The results obtained from HYSYS were diligently compared with
the ideal design calculations and the deviations were noted.
Pressure Selection
Figure VI.1.2: Top and Bottom Pressure Selection Graph.

Based on the case study conducted, a top pressure of 15 bar was selected, with
a pressure drop assumption of 0.4 bar. The cold and hot utility corresponding to
the selected pressure was the determining factor.
Table VI.1.1: The effect of top pressure against the suitable utility.
Top
Pressure
1 bar
10 bar
15 bar
Top
Temperature
-42 C
25 C
45 C
Bottom
Temperature
10 C
85 C
110 C
Utility Choice
(Cold + Hot)
Refrigerant + Steam
Chilled water + Steam
Cooling water + Steam
Verdict
X
X
In order to save on utility cost (energy consumption), the use of a refrigerant or

chilled water for the condenser was avoided. Hence, a top pressure of 15 bar
58 | P a g e
A.B. Verasingham
was selected. Low pressure steam is suitable for all the mentioned pressures.
K-Value Calculation
The manual K-value was calculated using the Antoine equation and constants
from Yaws Handbook. It was found that the deviation between the manual
calculations and HYSYS was between 1-5% for the k-values. However, the alpha
values using both the manually calculated k-values and the HYSYS k-values
remained constant.
Distribution of Non-Keys
Initially it was assumed that all the butane is at the bottom. Upon, the
calculation of the distribution of non-key components, the assumption was
deemed acceptable as butane registered a value of 0.00007 (negligible) in the
top product.
Bubble Point and Dew Point Calculation
It was found that the HYSYS k-values satisfied the dew and bubble point
condition of xi,2 =1 and yi,3 =1. The deviation of the manual and HYSYS
bubble and dew points were approximately 2%.
Reflux Ratio Optimization
A range of reflux ratio, R from 1.1Rmin to 4 Rmin was taken and the optimum R
was selected based on both the operating cost and the capital cost. The lower
the number of stages, the lower the operating cost but the higher the energy
required for the utilities. Based on DC-101 Figure 3, the curve started to stabilise
after 1.8Rmin, hence a R of 2Rmin was selected as it is the most optimum reflux
ratio.
59 | P a g e
Number of
Stages, N,t
A.B. Verasingham
A Graph of Number of Stages

against Reflux Ratio .
25
20
15
10
5
0
0
Reflux Ratio, R
Figure VI.1.3: A graph of number of stages against reflux ratio.

Efficiency and Actual Number of Trays
A more realistic comparison can be concluded after factoring the overall column
efficiency. Thus, the comparison of the Rmin and Nmin was not focused on. DC-101
operates with an efficiency of 64%.
Table VI.1.2: Manual and HYSYS Value Comparison.
Criteria
Reflux Ratio, R
No of Actual Stages, Na
Actual Feed Entry, Nf
Plate Spacing, m
Column Diameter,m
Column Height, m
Downcomer Area,m2
Net Area, m2
Active Area, m2
Hole Area, m2
Weir Length, m
Manual Calculation
2.3114
15
7
0.35
0.95
6.22
0.078
0.63
0.55
0.11
0.7125
HYSYS Value
3.2945
20
10
0.4
1.2
8.14
0.097
0.84
0.74
0.14
0.91
Deviation
43%
33%
43%
14%
26%
31%
24%
33%
35%
27%
28%
It can be observed from Table VI.1.2 that the deviation between the manual and
HYSYS values are relatively large.
Manual Calculations vs HYSYS
HYSYS values tend to deviate possibly due to improperly selected
thermodynamic models, inadequate model parameters and plant data
inconsistency. In this study, the SRK property package was selected as it
contains enhanced binary interaction parameters for all library hydrocarbon pairs.
Hence, the deviations are inevitable and can be accepted. Apart from that values
obtained from graphs through manual calculation could possibly have human
errors. In conclusion, the manual calculations were selected as HYSYS tends to
take overestimate values.
60 | P a g e
A.B. Verasingham
Column Internal Design
The top diameter was calculated to be 0.3166 m whereas the bottom diameter
was 0.8888 m. A diameter of 0.95 m was selected with the use of a nominal pipe
size of 36 inches. The calculated height was 6.2232 m with a height to diameter
ratio of 7; satisfactory as it is less than 20. Based on the column diameter, it was
found that trays are more suitable as compared to packing. Packing is usually
used for columns with a diameter of less than 0.7 m (0.95 m > 0.7 m).
Table VI.1.3: Type of Tray Selection.
Criteria
Cost
Pressure Drop
Maintenance
Bubble Cap
High
High
High
Sieve Trays
Medium
Low
Low
Valve Trays
Low
Low
Low
It was concluded that the most economical type of tray would be the sieve trays.
Sieve trays are inexpensive, efficient with high vapour flow rates (entering feed
has a high vapour flow rate), has a low pressure drop and are easy to clean.
Material Selection
High carbon steel ASTM A304 was adjudged fit and the corrosion resistivity to
propane, butane and pentane was checked. Apart from that, high carbon steel
has a high tensile strength which can withstand high pressures. Hence, carbon
steel was the more economical choice compared to stainless steel 304.
*The detailed manual calculations can be found in Appendix AIV. VI. 1.
61 | P a g e
A.B. Verasingham
Equipment Specification Sheet
Equipment Type
Item Code
Service
Author
Supporting Calculation
Drawing number
Separator (Distillation Column)

DC-101
Appendix AIV. VI. 1
D-DC-101
Design Data
Design Pressure
Operating Pressure
Overhead Pressure
Bottom Pressure
Overhead Temperature
Bottom Temperature
Feed Flow Rate:
Feed Temperature
16.72
15
15
15.4
43.88
104.88
3647.61
78.80
bar
bar
bar
bar
o
C
o
C
kg/h
o
C
Column Specification
Number of trays
Feed Tray Location
Reflux Ratio
Column Diameter
Column Height
Total Column Pressure Drop
Liquid Flow Pattern
Condenser Type
Reboiler Type
14
8
2.31
0.95
m
6.22
m
0.4
bar
Cross flow (Single Pass)
Total
Partial
Hydraulics Design
Type of Tray
Material of Construction
Tray Spacing
Tray Thickness
Column Area
Downcomer Area
Net Area
Active Area
Hole Area
Weir Length
Weir Height
Hole Diameter
Hole Pitch
Number of Holes Per Tray
Downcomer Backup
Sieve Tray
High Carbon Steel ASTM A304
0.35
m
5
mm
0.71
m2
0.078
m2
0.63
m2
0.55
m2
0.11
m2
0.7125
m
50
mm
5
mm
10
mm
5350
191.34
mm
62 | P a g e
A.B. Verasingham
63 | P a g e
T.Y. Kim
VI.2 Equipment Design for SC-101

MODULE CODE
GROUP
ACADEMIC SUPERVISOR
EQUIPMENT
DESIGN
SUPERVISOR
NAME
STUDENT ID
DATE OF SUBMISSION
AUTHORS
NAME
H83DPX
4
Prof. Dominic Foo
Dr. Lau Phei Li
Mr. Rafil
Kim Taeyeon
013461
18th April 2016
STUDENT ID
013802
Chan Joel Kai Chin
011032
Fidelia Prasetya
Soh Yi Shin Elaine
011494
013332
PROGRAMME
Meng Chemical with
Meng Chemical Engineering

Selangor, Malaysia
F | Page
T.Y. Kim
VI.2.1.General Sizing and Overview

Scrubber is required in the pre-treatment process. It removes carbon dioxide
from the feed gases with 30% mono-ethylamine at about 40 and 4 bar. The
operating conditions are 38 and 3.8 bar. The hydrocarbon reach vapour is fed
into the scrubber at 920kmol/hr (=4.76594kg/s). To successfully remove 90% of
CO2 at the condition, 30% MEA must be fed at 83.772kg/s.
Scrubber is a packed bed absorption column designed base on staged process.
Integrated form of the differential equations is useful tool to design the
absorption column. The primary equation is given in equation 11.97 of
(R.K.Sinnott, 2010) as below where Z is the packing height required.
1
(Eq. VI.2.1.1)
=
(Eq. VI.2.1.2)
= +

(Eq. VI.2.1.3)
= 0.011 ()0.5
(
1.11 0.33
)
(
)
0.305
3.05
(Eq. VI.2.1.4)
The most effective number of stages for the scrubber is 7 and the diameter of
the column is 2.33m. Total packing height is 10m and extra 2m is needed for 1m
is required for liquid distributor and the other is for level increase at the bottom
of the vessel. The vapour is fed at a point above 0.8m from the bottom of the
scrubber and MEA is fed from the top of the scrubber. This is because gases can
flow up to the top of the scrubber while MEA runs down through the packing
voids due to gravity. It enables 0.7m of maximum solution level increase. It was
chosen that the pressure drop should not exceed 22 mm(water)/m(packing
height). The detailed calculation is shown in the Appendix AIV. VI. 2
VI.2.2. Internal supports and packing materials
Liquid distributor is required to distribute MEA evenly throughout the scrubber
packings. Weir Trough type of liquid distributor is a suitable device in this case.
The packing materials used for the CO2-MEA scrubber is Intalox. Saddle, Ceramic
with diameter of 38mm. Packing support is required to support the random
packing, Intalox Saddles. It supports the weight of wet packing while allowing
the free path for the gas and liquid solvents for scrubbing. According to
(R.K.Sinnott, 2010), gas injection is the best design of packing support because
it provides gas inlets above the level of liquid flow from the bed. Hence, it is
used to support the packing.
64 | P a g e
T.Y. Kim
VI.2.3. External supports

Wall thickness and Stresses
TableVI.2.3.1. Design for wall
Material
Carbon Steel
Thickness of Wall = [P D / 2 f J - P] +c
Operating Pressure
3.80
bar
0.38
N/mm3
Design Pressure, P
3.08
bar
0.308
N/mm3
Innder Diameter, D
2.33
0.002326
mm
Permissible Stress, f
95.00
N/mm2
Joint Efficiency, J
0.85
Corrosion allowance, c
2.00
mm
Tickness of wall
2.00
mm
Minimum Thickness of wall
9.00
mm
Hence, the wall thickness can be taken as 9mm.

Table VI.2.3.2.: Axial stress due to pressure
( )
380000
N/m3
308000
N/m3
2.33
m
9
mm
2
mm
2.55827E-05
N/mm2
() =
Pressure
Design pressure
Inner Diameter, Di
ts
Corrosion allowance
f(AP)
0.38
0.308
0.002326
N/mm3
N/mm3
mm
0.025583
N/m2
Hence the axial stress due to pressure is . /

Gasket and bolt
Table VI.2.3.3.: Gasket and bolt
Width, N
10
mm
(Sinnot,
Material
asbestos
(Sinnot,
Gasket factor, m
2
(Sinnot,
Gasket thickness, t
3.2
mm
Min. Design seating, Ya
11
N/ mm2
Basic gasket seating width, bo
N/2
5.00
mm
Effective gasket seating width, b 2.5(bo)*(1/2)
6.25
mm
Di
2.33
m
Do
2.34
m
Mean Diameter, G
2.33
m
2334.70
Bolt Load due to gasket, (ml) = b G Ya
W(ml)
5.04E+05
N
Design pressure, P
3.08
bar
0.308
(m2 ) = 2b G m P] + [(/4) G2 P]
W(m2)
1.38E+06
N
Bolt material
Carbon Steel
minimum bolt area required Ab f = W(m)/fb
2005)
2005)
2005)
mm
N/mm2
65 | P a g e
T.Y. Kim
Maximum allowable bolt stress, fb = 125N/ mm2

Ab f
1.10E+04
mm2
0.011
Number of bolts
186.78
bolts
D2
74.98887062
mm2
8.659611459
mm
Diameter of bolts
0.866
cm
m2
Flange, Head and Nozzle

Table VI.2.3.4..: Thickness of flange, head and nozzles
Flange
thickness
29.8641964
mm
Head
Material
Stainless steel
Design pressure
0.308
N/mm2
thickness
4.70
mm
Nozzle
Material
carbon Steel
Joint efficiency, J
0.85
thickness
0.6978
mm
No corrosion allowance, since the material is carbon steel. Take the minimum
nozzle thickness of 3 mm
Table VI.2.3.5..: Stress due to dead load
a) compressive stress due to weight of shell up to distance X
Do = Di + 2ts
Do
2.34
shell material
7700
kg/m3
0.077
Xkg/cm2
0.077 X
kg/cm2
(fds
fds
= sX)
b) compressive stress due to weight of insulation at height X

Material
Asbestos
Thickness of insulation
100
mm
Density of insulation
575
kg/m3
Diameter of insulation, Dins = Do for large diameter column

fdins = [ Dins t ins ins X ]/[ Dm (Ds c)]
fdins
8.25E+03
X N/m2
8245.95 X
N/m2
c) compressive stress due to liquid in column up to height X

L
999.99
kg/m3
fdliq = Di2 XL4 Dm (t s -c)

fdliq
3.31E+05
XN/m2
d) compressive stress due to attachment

Density of packing
670 kg/m3
66 | P a g e
T.Y. Kim
(Intalox. Saddle, Ceramic)

packing weight = [ Di2 X pck g ]/ 4
27921.73613
XN
27921.7 X
Appx. Head weight
35000
Ladder weight
1600
XN
packing weight
fd
sum of packing and ladder

29521.73613
= ( total weight)/(Di (t s c)) = fd = ((29521.7X + 35000) )/(Di (t s c))
0.051144893
( Di (t s c))
29521.7X+35000/0.0511
fd
577217.6706
684330.2976
fd
577217.7X+684330.29
e) stress due to wind
fwx = Mw / Z
Mw = [0.7 pw Do X 2 ]/2
0.05 vw 2
pw
assumed
velocity of wind, vw
100
Mph
44.7
m/s
N/m2
pw
from coulson
1280
Mw
1049.979209
X2
Z = [ Do 2 (t s c)]/4
Z
fwx
0.030199051
34768.61629
f) Determine X
X2
ft max = 95 106
ft max = f + fap fdx
= 34768.61629 X 2 + 0.025583 577217.7 + 684330.29 = 17.7

g) Summary
fAP
0.02558274
N/m2
fs
13629
N/m2
fd(ins)
1.46E+05
N/m2
fd(liq)
5.86E+06
N/m2
fd
10901083.07
N/m2
fwx
10892659.8
N/m2
Total
2.78E+07
N/m2
67 | P a g e
T.Y. Kim
VI.2.4. Data Specification Sheet

Equipment No.
Sc-101
Description
Removal of CO2
Equipment Type
Scrubber
Supporting Calc.
AIV. VI.2
Author
Kim Tae Yeon
Drawing No.
Figure VI.2.1
Design Data
Design Pressure
3.8
bar
o
Design Temperature
38.0
C
Solute Loading to solvent
0.5
mol CO2/mol MEA
Type of solvent
30% MEA
Operating Mode
Continuous
Operating Type
Isobaric
Internal Condition: Vapor
Flow Rate
4.6
kg/s
Density
2.7
kg/m3
Design Pressure
3.8
bar
o
Design Temperature
38.0
C
Internal Condition: Liquid
Flow Rate
82.2
kg/s
Density
999
kg/m3
Viscosity
0.000994
Nm/s2
Surface Tension
0.49
N/m
Operating Data
Packing
Type and Material
Intalox Saddle, Ceramic
% void
73-76
%
Size
38
mm
Bulk Density
625
kg/m3
Surface area
194
m2/m3
Packing Factor, Fp
170
m-1
Internals
Number of stage
7
Column Diameter
2.4
m
Height of Tower
12
m
Height of Packing
10
m
Maximum Pressure Drop
bar
Mechanical Data
Packing support
Gas Injection
Liquid Distributor
Weir Trough
Wall Material
Carbon Steel
Wall Thickness
9
mm
Axial Stress due to pressure
0.026
N/m2
Stress due to Dead Load
27.8
MN/m2
Bolt Material
Carbon Steel
Bolt Quantity
187 bolts
Bolt diameter
0.866
cm
Gasket Material
Asbestos
Flange Thickness
3
cm
Head Material
Stainless Steel
Thickness of head
5
mm
Nozzle Material
Carbon Steel
Nozzle Thickness
3
mm
Packed Column Data Specification Sheet
68 | P a g e
T.Y. Kim
VI.2.5. Scrubber drawing

Figure VI.2.5.1.:Drawing of scrubber and its packing
Intalox Saddle, ceramic packing material
Weir Trough Liquid Distributor
Scrubber cross sectional view
69 | P a g e
J.K.C. Chan
VI.3 Equipment Design for RX-101

MODULE CODE
GROUP
ACADEMIC SUPERVISOR
EQUIPMENT
DESIGN
SUPERVISOR
NAME
STUDENT ID
DATE OF SUBMISSION
AUTHORS
NAME
Fidelia Prasetya
Kim Tae Yeon
Soh Yi Shin Elaine
H83DPX
4
Prof. Dominic Foo
Dr.Suchithra Tangalazhy Gopakumar
Mr. Rafil
Chan Joel Kai Chin
011032
18th April 2016
STUDENT ID
013802
011494
013461
013332
PROGRAMME

Selangor, Malaysia
F | Page
J.K.C. Chan
VI.3.1 Overall Summary of Equipment Design

The type of reactor that is being design and adapted for reactor-101 is an
isothermal shell and tube packed bed reactor (PBR) that has a catalyst bed
loading capacity, B of 3 ton. The catalyst specification along with the analyzed
and predicted chemical reaction kinetics that happens in the active sites of the
catalyst can be referred at Section VI.3.2: Catalyst Specification and Predicted
Chemical Reaction Kinetics.
In Section VI.3.3: Reactor Design Consideration and Comparison of Reactors; a
few key design starting points will be made and assumed so that the best
reactor which suits the process demand, safety, economy and also
environmental considerations can be selected by comparing it among a few
commercially available reactors offered in the industry.
Moving on, after selecting the best reactor; in Section VI.3.4: Mass Balance
Algorithms & Equipment Specification Calculations. The reactor is simulated with
MATLAB simulation algorithms to solve ODEs that describe the various
differential mass balance and pressure drop equations which become the starting
point for reactor sizing and other important specification calculations needed to
be included in the equipment loading sheet (Section VI.3.5) for the perusal of
vendors.
In section VI.3.5: Equipment Loading Sheet & Drawing Sketches, all the
calculated equipment sizing and specification data will be included in the
equipment loading sheet table for fabrication works by vendors. On top of
that, equipment drawing sketches will also be included to provide a visual
and comprehensive manual for fabrication works.
Finally, in section VI.3.6: Extensive Individual Equipment Design Appraisal and
Suggested Further Improvements; important special features of this reactor
will be highlighted so that the reactor can stand-out among previous
conventional reactors being used. Moreover, various further improvement
points are also suggested so that future works or research can be done in the
areas mentioned.
VI.3.2 Catalyst Specifications and Predicted Chemical Reaction Kinetics
The catalyst used in this reactor is of alumina silica based zeolite that has 3 or 4
helical wound segments about a straight line axis (axis of extrusion). The pellet
is completely filled and has no perforation unlike hollow counterparts. A
conventional catalyst pellet may be shaped into hollow cylinders, spheres or
even rashcig-rings but trilobe extrusion pellets can reduce pressure drop
across the catalyst bed (Bambrick, 1987). However, the downside of this
unique shape is that the crush strength of the pellet is about the crush
strength of a straight counterpart pellet (Bambrick, 1987).
70 | P a g e
J.K.C. Chan
Table VI.3.2.1 Catalyst Specification and Details

Supplier
Johnson Mathhey Process Technologies (U.
K.)
Catalyst Series
KATALCOJM61-1T
Composition
NiO2/MO/Alumina Zeolite Base (MO/HZSM5)
Purposes
Hydrogenation, Olefin Saturation Aromati
zation
Physical Properties (typical)
:
(i) 2.5
(i) Diameter (mm)
(ii) Typical Loaded Density
(ii) 590 / 35
3
3
(kg/m )/(lb/ft )
(iii) Trilobe Extrusion
(iii) Shape
VI.3.2.1 Predicted Chemical Reaction Kinetics
Due to complexity of dual conversions of methane and ethane to aromatic
products, only methane conversion activities are being simulated and
considered whereas ethane conversion activities are assumed to
function by conversion and selectivity factors in the general mass
balance.
The non-oxidative dehydroaromatization reaction being described in this passage
is taken from (Enrique Iglesia, 2002) which are:
(i) Breaking of C-H bonds in CH4 to form CHx radicals
(ii) Recombination of CHx radicals to form at least C2 hydrocarbons
(iii) Oligomerize and cyclize the C2 groups into thermodynamically favoured
aromatics
Chemical Reactions:
(1) 2CH4 C2H4 + 2H2
(2) 3C2H4 C6H6 + 3H2
(3) C6H6
+ 2C2H4 C10H8 + 3H2
Rate constant values, k are provided by (Enrique Iglesia, 2002), however the
accompanying frequency factor, A and Activation Energy, Ea are not provided
which proves to be a problem when describing the chemical kinetics in the form
of Arhenius law in simulation software such as HYSYS. After extensive research,
it was suggested in (Scott, 2010) to apply Polanyi-Semenov correlation to
determine the activation energy of the following chemical reaction, where values
of Ea* and p are given in (Masel, 2001) pg. 254
Ea=Ea*+pHRX
(Equation VI.3.2.1)
Table VI.1.2.2 Chemical Reaction Kinetics (Enrique Iglesia, 2002)

Reaction
1
2
3
-1
-1
Rate Constant, k
0.04 s
4.2 s
1.2x107 cm3mol-1s-1
(T= 973 K)
71 | P a g e
J.K.C. Chan
Frequency Factor, A (h-1)

261.0676
Activation Energy, E a (kJ/ 445.664x103
kmol)
27.4121x103
626.676x103
78.3203x106
621.862x103
VI.3.3 Individual Equipment Design Basis & Considerations

VI.3.3.1 Selection of Type of Reactor
In table VI.1.3.2.1, based on (Hutchings, 2013) 3 different reactors which
are applicable and currently used in the industry will be compared. The 3
reactors are further narrowed down within a few important factors.
Table VI.1.3.1 Table of Comparison on Various Type of Reactors (Hutchings, 2013)
Type of Reactor
s
Product Yield %
Coupled Reactor (OCM

)
Higher product yield % t
han conventional packed
bed reactors (PBR) but l
ower than membrane rea
ctor
Catalyst Regene Carbon soot on catalyst
ration
pellets are effectively re
moved by allowing flow
of oxygen gas
Economical Asp
ect
Membrane React
or
Highest Product Yi
eld % among com
parison due to the
selective removal
of H2 gases
Hydrogen gas rem
oval reduces carbo
n soot formation t
hus catalyst can la
st longer
Most Expensive as
tubular materials a
re made from me
mbrane materials
More expensive than con

ventional PBR as coupled
reactors must be accom
panied with other auxiliar
y sub-reactors
Safety Aspect
Quite dangerous as oxyg Safer than convent
en is being mixed togeth ional PBR but high
er in the reactors
temperature oper
ation is not dealt p
roperly
Environmental A Reactor does not produc Reactor does not p
spect
e waste stream and deac roduce waste strea
tivated catalyst are relati m and deactivated
vely benign
catalyst are relati
vely benign
Involves more parameter Most complicated p
Process Control
sensors and transmitters rocess control desi
Aspect
compared to convention gn as selectivity in
al PBR design
membrane cannot
be controlled by c
onventional proces
s schematic
Shell-Tube Packe
d Bed Reactor
Higher product yield
% than conventional
packed bed reactors
(PBR) but lower tha
n membrane reactor
Catalyst regeneration
cycle is the same w
ith conventional PBR
Slightly more expens

ive than conventional
PBR but the cheape
st among comparison
Safest reactor compa
rison as the high te
mperature operation
is safely controlled
Uses recycled residu
al gases to keep the
reactor at 700 C
Most reliable and si

mplest process contr
ol because of direct
process control sche
matic
72 | P a g e
J.K.C. Chan
= Most advantageous among comparison

In conclusion, the best choice will be shell tube packed be reactor due to
the expounded factors in the table.
VI.3.3.2 Mass & Energy Balance as Starting Point for Design Basis &
Considerations
According to the manual calculated mass balance approximately 4236.99
kmol/h of methane and 209.66 kmol/h of ethane are being passed into the
reactor with other non-reacting components. Therefore, considerations have to
be made for the reactor to allow high volumetric flowrate of reactants and
that the vessel must be able to accommodate high pressure conditions.
As previously mentioned in the process overview section, the operating pressure
of the reactor is at 3.6 bar while the operating temperature is at 700C. It was
also found that the chemical processes involved in the reactors are endothermic
in nature and therefore approximately 15418.29 kW worth of heat energy is
needed. Since, the process is endothermic in nature, therefore an internal
heating system which follows a shell and tube design is utilized to keep it at
isothermal condition. The high temperature operation at (700 C) is crucial
because methane conversion will drastically decrease at lower temperatures.
Since, conventional superheated steam can only be heated up 300 C, therefore
combustion at the shell side of the reactor is needed by burning recycled
residual fuel gases from DC-101 because combustion of hydrocarbon gases
can reach up to 1000 C which is sufficient enough to maintain the heat in the
tubes containing reactants and catalyst.
VI.3.4 Mass Balance Algorithms & Equipment Specification Calculations
VI.3.4.1 Mass & Energy Balance Algorithms in MATLAB
In developing the mass balance algorithm used to simulate the desired reactor;
entering reactant molar flowrates, volumetric flowrate and inlet pressure are
taken into account to develop 7 ODE equations for different components
(A=methane, B=ethene, C= benzene, D= naphthalene, E= hydrogen, pd=
pressure drop ratio and T=temperature).
[ki(Cto)(Fi/Ft)(y)]j

2 0
(r )H UA(TT )
Ft=Fi
F Cp
(Equation
VI.3.4.1)
(Equation
VI.3.4.2)
(Equation
VI.3.4.3)
(Equation
VI.3.4.4)
73 | P a g e
J.K.C. Chan
The full and complete algorithm used can be referred at appendix (VI.3.4.2.2:
MATLAB Simulation Algorithm). Moreover, the accompanying graphs from
MATLAB for all of the 5 components, pressure drop and temperature profile can
be seen at appendix (AIV.VI.3.4.2.5: Products, Pressure Drop , Methane
Conversion & Temperature Profile Graphs).
VI.3.4.2 Discussion and Findings from Graphs Obtained through MATLAB
Algorithm
All of the 5 final product graphs are simulated at 1000 kg instead of
3000 kg because the conversion percentage difference between 3000 kg
against 1000 kg is very small at (6.2x 10-4) margin. Therefore, the small
amount of product conversion reduction is considered as a buffer at which in
real scenario product yield percentage are lower. Moreover, from the graph
methane conversion versus weight of catalyst , it was found that the
methane conversion percentage reaches a saturation value at 3000 kg
of catalyst used onwards, therefore the choice to use this value of catalyst
weight loading is reasonably justified. Based on the temperature profile graph,
temperature decrease is quite small at (0.85C), therefore the indirect
heating by recycled leftover gases is performed periodically instead of
constant combustion which reduces the risk of shell and tube meltdown.
Moreover, simulated pressure drop is 1.8 bar, which means that exiting
pressure drop is 1.8 bar which is approximately half of the inlet pressure.
VI.3.4.3 Reactor Specification Calculations
Refer to appendix (AIV.VI.3.4.3.1: Alpha and Beta Calculation) to review all of
the calculations for alpha, and beta, values in the pressure ODE equation
used in MATLAB algorithm. On top of that, the considerations and calculations
made for estimating the diameter of the reactor, the space time, ratio of
diameter against length, L/D and pressure drop of reactor can also be reviewed
at the appendix section (AIV.VI.3.4.3.3: Space Time, Ratio of L/D Calculation &
Pressure Drop Calculation). Moreover, the conversion, selectivity and yield
percentage of methane and the expected products can be reviewed at the
appendix section (AIV.VI.3.4.3.4: Conversion, Selectivity and Yield Percentage of
Methane and Expected Products).
VI.3.5 Equipment Loading Sheets and Drawing Sketches
VI.3.5.1 Equipment Loading Sheet
Table VI.3.5.1 Equipment Loading Sheet for Reactor-101
Specifications
General Specification
Design Pressure (bar)
Operating Pressure (bar)
Pressure Drop Ratio
Values
Outlet Pressure (bar)

Design Temperature (C)
1.8
700
Operating Temperature (C)
7005
3.6
3.6
0.5
Description
From graph of pressure drop versus cataly

st weight
74 | P a g e
J.K.C. Chan
Catalyst Bed Specification

Type of Catalyst
Weight of Catalyst Bed (kg)
3000
Volume of Catalyst (m3)

Space Time (s)
Density of Catalyst (kg/m3)
5.34
1.4375
560
Shell Specification
Diameter of Shell Section Re
actor, Ds (m)
Length of Shell, L (m) (Exclu
ding Head)
Length of Shell, Lh (m)
(Including Head)
Cross-Sectional Area of Shell
Section (m2)
Volume of Shell (m3)
Appendix (VI.1.5.2.3)
From Johnson Matthey Catalogue for KATA
LCO series
Industrial Rule of Thumb (2-3 m)
By using ratio of L/Ds of 1:3
11.80
7.07
Cross-Sec. Area of Shell =Ds2/4
63.63
Volume of cylinder =(Cross. S. A) x (L)
Length of Head (m) (In/Out)
1.4
Ratio Shell Length against Di

ameter, L/D
Tubing Specification
3:1
Number of Tubes
200
Number of Tubing
Banks
Internal Diameter of Tube (
m)
Cross-Sectional Area of each
Tubing (m2)
Cross-Sectional Area of total
Tubing (m2)
Length of Tube (m)
10 (20 tubes in e
ach bank)
0.2027
0.0323
6.46
9
0.008
Schedule 40 Thickness
Nozzle Specification
Molybdenum Alumina Zeolite

Obtained from Conversion Versus Weight o
f Catalyst
(m)
Inner Diameter of Shell Nozzl

e (m)
Outer Diameter of Shell Nozzl
e (m)
Inner Diameter of Head Nozzl
e (m)
Outer Diameter of Head Nozz
le (m)
Total Number of Nozzle Fin
0.50
Length of Nozzle Fin (m)
0.80
Manual Calc. based on Cross-Sec. Area of

Shell & Cross-Sec. Area of each tubes
(McNichols: Industrial Architectural Hole Pr

oduct Solution Since 1952, 2010)
Cross-Sec. Area of Tubing =Ds2/4
Cross-Sec. Area of total Tubing = Numbe
r of tubes x Ds2/4
Similar to length of shell excluding head
(McNichols: Industrial Architectural Hole Pr
oduct Solution Since 1952, 2010)
0.80
3.00
3.20
6
Function to throttle incoming velocity of th

e flowrate
Miscellaneous
Inner Diameter of Manhole (
m)
Outer Diameter of Manhole (
m)
Skirting Height (m)
0.80
Skirting Thickness (m)
0.30
1.00
0.50
75 | P a g e
J.K.C. Chan
VI.3.5.2 Equipment Drawing Sketches

VI.3.5.2.1 Explaining Drawing Sketches
Briefly, the technical drawings are divided into 3 views at different
directions; looking at the cross-sectional drawing, recycled residual fuel
gases travels through shell nozzle 1 to the shell side where the internal
combustion occurs and the exiting flue gases exits through shell nozzle 4. The
use of recycled residual gases further enhance the environmental
sustainability of this design. On top of that, shell nozzle 2 & 3 are for
entering and flushing of CO2 gases used as extinguishers during
emergency where temperature increase is very high which may cause
meltdown. Moreover, reactant gases travel at the tube side through 10
banks of 5 by 4 tubes (200 tubes in total) where it reacts with 15 g of
catalyst pellet in each tube and the product gases are collected at the end.
(Refer to Drawing Sketches VI.3.5.2.1 - 3.5.2.3)
VI.3.6: Extensive Individual Equipment Design Appraisal and Suggested
Further Improvements
In a nutshell, the design of the reactor has gone through a thorough
process that takes into account considerations that covers mainly on process
nature, economical, safety, environmental and process control aspect which are
very important for the safe and efficient operation of the reactor that satisfies
the process demand. Moreover, one of the main highlights of this design is the
selection of shell and tube packed bed reactor which is very effective in keeping
the reactor operating at isothermal condition, the backup CO2 stream used as
extinguishing medium in case of an emergency where flow control of
recycled fuel gas fails which leads to very high temperature increases. The
integration of tube banks design that is designed optimally to fit 5 by 4 tubes in
a bank allows the best possible contact surface area with the combusted
recycled gas that supplies heat. Moreover, the use of recycled fuel gases fits
the criteria of environmental sustainability and energy conservation. This
proves that the design is very safe, applicable, green and relatively affordable
for industrial usage that involves huge and complex processes.
However, there are some points of further works that can be done on this
design which is the introduction of membrane technology which assist
hydrogen transport removal (Enrique Iglesia, 2002). It was found that by
removing hydrogen simultaneously, the product yields increase tremendously.
Moreover, the selection of membrane material is very important as
considerations have to be taken to the thickness of the membrane layer for
resilience at high temperature but with the setback of lower hydrogen diffusion
rates. Thus, this design can be further improved with the integration of
membrane technology. For further cleaner production strategy relation, refer to
(Environmental Protection VII.7.1: Less Carbon Soot Production by RX-101 with
Membrane Technology Integration for H2 Gas Removal)
76 | P a g e
Drawing Sketches VI.3.5.2.1 - 3.5.2.3
J.K.C. Chan
77 | P a g e
F. Prasetya

MODULE CODE
GROUP
ACADEMIC SUPERVISOR
EQUIPMENT
DESIGN
SUPERVISOR
NAME
STUDENT ID
DATE OF SUBMISSION
AUTHORS
NAME
H83DPX
4
Prof. Dominic Foo
Dr. Timm Joyce Tiong
Mr. Rafil
FIDELIA PRASETYA
011494
18th April 2016
STUDENT ID
013802
Chan Joel Kai Chin
011032
Kim Tae Yeon

Soh Yi Shin Elaine
013461
013332
PROGRAMME
MEng Chemical with
Department of Chemical Engineering, University of Nottingham Malaysia Campus

Selangor, Malaysia
F | Page
F. Prasetya
The purpose of designing this distillation column is to separate the residual gas
from the mixture. Hence, 99% purity of benzene could be achieved in the next
distillation column. N-pentane has been set as the light key and benzene as the
heavy key. N-pentane in the bottom has been set to 0.01 wt%.
The first step is to determine pressure and temperature of dew and bubble point.
It was obtained by manual calculation (refers to appendix IV.VI. 4 for detailed
calculation). A simulation is needed in order to justify the selection of pressure
and temperature.
Figure VI.4.1 Case Study Obtained From Hysys
Based on the graph above, it is shown that the pressure range (3-5 bar) that has
been used to estimate the dew and bubble point are considered acceptable. The
temperature range for the selection of the condenser and reboiler also
considered satisfying. Thus, the operating condition for dew and bubble point are,
Dew point
: 3.2 bar and 48.50oC
Bubble point : 4.2 bar and 137.74oC
After dew and bubble point are obtained, determination of reflux ratio can be
done as the next step. In the graph shown below, as the reflux ratio increase,
the number of theoretical stage and height of the column will be reduced. Hence,
the total cost needed to build the equipment will decrease. The number of stage
start to show a constant value when the reflux ratio is 1.5. Hence, reflux ratio of
1.5 is taken for the design (R= 1.5 Rm, R= 4.335).
Number of Stage
Graph of Reflux Ratio against Number of Stages
20
15
10
5
0
0
0.5
1.5
2.5
Reflux Ratio
Figure VI.4.2: Reflux ratio affects the Minimum Number of Stages
Since the reflux ratio has been obtained, the number of stage needed can be
78 | P a g e
F. Prasetya
calculated. The number of stages needed for this distillation column is 9 stages.
However, since the efficiency of the column is only 45.50%, the actual number of
stages needed is 19 stages (including 1 reboiler). Refers to Appendix IV. VI.4 for
detailed calculation
The diameter of the column that has been obtained based on manual calculation
for the top part is 0.450 meter and for the bottom part is 0.712 meter. The
bigger diameter which obtained from the bottom part will be used. Based on the
nearest standard pipe size (BS 1600), outside diameter of 0.762 meter will be
taken as the diameter for the distillation column. The diameter from the manual
calculation has been compared to Hysys and gives the same result. Besides
diameter, several parameters have been compared with Hysys as well.
Table VI.4.3 Comparison of Some Parameters between Manual and Hysys
Parameter
Diameter, m
Plate Spacing, m
Hole Area, m2
Active Area, m2
Section Height, m
Flooding Percentage,
%
Number of holes
Manual
0.762
0.45
0.018
0.291
11.10
69.91
Hysys
0.762
0.61
0.032
0.318
11.58
52.59
892
1013
Based on comparison table, the other parameters except for the diameter are
having different values. This might be occur due to assumption made in the
manual calculation. For example, the assumption of downcomer area will affect
the value of active area. In manual calculation, it has been assumed that the
downcomer area is 18%. The flooding percentage of the manual calculation is
also bigger than the simulation.
Based on rule of thumb, determination of height of the column can be calculated
by multiply the number of trays and also the tray thickness with the plate
spacing with additional 1.2 m on the top and 1.8 m at the bottom (Woods, 2007).
The ratio of the height to diameter of the column is 14.69 (It is still considerably
good since it still less than 20 or 30).
The diameter of the column is relatively small for tray column. However it has
already passed the margin between pack and tray column. Hence, tray column is
still chosen for designing this distillation column. Type of tray that has been
chosen was sieve tray. Sieve tray is relatively cheaper and more efficient
compare to other types of tray due to simple design. It also has the lowest
pressure drop compare to other type of trays.
Since sieve trays are used, the manual calculation of pressure drop of the
column is considerably small (approximately 0.19 bar). As the pressure drop
gets higher, the duty of reboiler and condenser will also increase. However, it is
hard to maintain the constant pressure drop throughout the column since there
will be fluctuation. Therefore, higher pressure drop per plate is assumed (0.053
bar per plate) for the design of this distillation column.
79 | P a g e
F. Prasetya
Based on the calculation (refers to DC graph 8), the distillation column has been
designed by using single pass flow. Partial condenser has been used for this
process due to vapor top product (residual gas) that needs to be separated from
the mixture.
Material that has been used to build this distillation column is carbon steel.
Carbon steel is commonly used for the construction of distillation column. The
components in the feed are also not corrosive with carbon steel. The price of
carbon steel is considerably cheaper compare to stainless steel. Hence, carbon
steel in the most suitable material to construct this distillation column.
80 | P a g e
F. Prasetya
Equipment Type
Item Code
Service
Author
Drawing number

Distillation Column
DC-102
Fidelia Prasetya
Appendix AIV. VI.4
D-DC102
Design Data
Design Pressure
Operating Pressure
Overhead Pressure
Bottom Pressure
Bottom Temperature
Feed Flow Rate:
Feed Temperature
4.62
3.20
3.20
4.20
48.50
137.74
128.30
97.00
bar
bar
bar
bar
o
C
o
C
kg/h
o
C
Number of trays
Feed Tray Location
Reflux Ratio
Column Diameter
Column Height
Liquid Flow Pattern
Condenser Type
Reboiler Type
19
5
4.335
0.762
m
11.190
m
1
bar
Single Pass Flow
Partial Condenser
Partial Reboiler
Hydraulics Design
Type of Tray
Tray Spacing
Tray Thickness
Column Area
Downcomer Area
Net Area
Active Area
Hole Area
Weir Length
Weir Height
Hole Diameter
Hole Pitch
Downcomer Backup
Sieve Tray
Carbon Steel
0.450
5.000
0.456
0.082
0.373
0.291
0.018
0.624
50.000
5.000
14.000
892
222.870
m
mm
m2
m2
m2
m2
m2
m
mm
mm
mm
mm
81 | P a g e
F. Prasetya
VI.4.1 Drawing of DC-102
82 | P a g e
Y.S.E. Soh

MODULE CODE
GROUP
EQUIPMENT
DESIGN
SUPERVISOR
ACADEMIC SUPERVISOR
DATE OF SUBMISSION
H83DPX
4
AUTHORS:
SOH YI SHIN ELAINE (013332)
Group members:
NAME
Arati
Banu
Verasingham
Kim Tae Yeon
A/P
Dr. Lee Lai Yee

Prof Dominic Foo
Mr. Rafil
18th APRIL 2016
STUDENT ID
PROGRAMME
013802
013461

MEng Chemical with
Chan Joel Kai Chin
011032
Fidelia Prasetya
011494

Selangor, Malaysia
F| P a g e
Y.S.E. Soh
VI.5 Equipment Design for Distillation Column (DC-103)

DC-103s objective: To produce benzene with purity greater than 99wt%.
Design Basis:
Benzene recovery in distillate: 98.5%
Light key (LK): benzene, heavy key (HK): toluene
[All non-keys (C4H10, C5H12 and C10H8) will only present in distillate or bottom
product.]
HK in distillate: 0.003, LK in bottom: 0.110
Product (benzene) purity: 99.6 wt%
Table VI.5.1: Material balance for DC-103
Component
C4H10
C5H12
C6H6
C7H8
C10H8
Feed
(kmol/h)
0.001
0.012
105.6
5.305
7.783
Zi,F
0.00
0.00
0.89
0.05
0.07
Distillate
(kmol/h)
0.001
0.012
104.1
0.313
0.000
yi,D
0.000
0.000
0.997
0.003
0.000
Sum
118.7
1.00
104.4
1.000
*For mass balance, please refer to section IV.3 Distillation Column 3
Bottom
(kmol/h)
0.000
0.000
1.585
4.992
7.783
14.36
Xi,B
0.00
0.00
0.11
0.35
0.54
1.00
Selection of Operating Conditions
Figure VI.5.1: Alpha against pressure
Figure VI.5.2: Top and bottom temperature against pressure
83 | P a g e
Y.S.E. Soh
From figure VI.5.1, it can be observed that alpha decreases with pressure. Besides,
both top and bottom temperature increases with pressure. This indicates that low
operating pressure is preferred as it has larger alpha (easier separation) and lower
operating cost. As the distillate will be sent to the storage tank and the bottom
outlet will be sent to another column to purify naphthalene, the operating pressure
of the column need not to be too high. However, the bottom product needs to have
sufficient pressure for it to enter the last distillation column (DC-104). Moreover, a
high operating pressure is also undesired as thicker wall will be required to
withstand the high pressure, thus increasing the capital cost.
Operating pressure of the column was chosen to be at 1.8 bar. Pressure drop of
column was estimated to be of 0.5 bar, hence the bottom pressure of the column is
2.3 bar.
Feed
Top
Bottom
Table VI.5.2: Feed, top and bottom conditions of column

Pressure/bar
Temperature/oC
2.2
113.0
1.8
97.4
2.3
164.2
Selection of Plate Type:

Sieve plate was chosen in this design. This is because it is the least expensive and
least prone to fouling as compared to bubble cap and valve plates. Besides, it is the
easiest to clean due to its simple structure. However, it only has a turn down ratio
of 2 and this means that it can only handle 50% to 120% of its design range
(Sinnott, Coulson and Richardson, 2005). Nevertheless, pressure drop over sieve
plates is the lowest compared to valve and bubble cap trays.
Other Design Details
Single-pass plate, vertical downcomer and equilateral triangular pitch are used in
this design.
Comparison of Manual Calculation with HYSYS Simulation:
Table VI.5.3: Comparison between manual calculation and simulation
Nm
Rm
Distillate (kg/h)
Bottom (kg/h)
Manual Calculation
HYSYS
Error (%)
8.19
0.758
8158.05
1581.24
9.44
0.862
8154.73
1584.43
13.29
12.09
0.041
0.201
There was about 12 to 13% difference in both calculated N m and Rm to the result
obtained from HYSYS. The difference is likely to be due to the assumption of ideal
system. As ideal system is assumed, Antoines equation was used to calculate the K
values which were subsequently used in the calculation of Nm and Rm. This might
have led to the difference between calculated and simulated values. On the other
hand, the calculated and simulated mass flow for both distillate and bottom are
quite similar. The difference between manual calculation and simulation is negligible
84 | P a g e
Y.S.E. Soh
as the error is less than 1%.

Selection of Reflux Ratio
The number of stages for different reflux were found by using Erbar-Maddox StageReflux Correlation (DC graph 10).
= 0.431
+ 1
Table VI.5.4: Number of stages at different reflux
1.1Rm
1.2Rm
1.3Rm
1.4Rm
1.5Rm
0.834
0.910
0.986
1.061
1.137
0.455
0.476
0.496
0.515
0.532
0.29
0.43
0.51
0.58
0.63
28.24
19.27
16.06
14.12
13.10
(Theoretical)
From the table above, the optimum reflux ratio is 0.986, which is 1.3 times of the
minimum reflux ratio. By using this reflux ratio, approximately 10 stages can be
reduced compared to that of using 0.833 as reflux ratio. It was also noticed that
beyond this reflux ratio the decrease in number of stages was not so significant.
Hence, the reflux ratio used in the following design is 0.986.
Efficiency and Actual Number of Stages
Overall column efficiency, Eoc= 58.4%
Actual number of stage, N= 28
Table VI.5.5: Number of stages in rectifying and stripping section
Number of stage in rectifying section
17
Number of stage in stripping section
11
Feed entering stage
17th
One of the assumptions made in designing this column is that all light non-key
components (C4H10 and C5H12) will only present in distillate while heavy non-key
component (C10H8) will only present in the bottom product. In order to justify this
assumption, Fenskes equation for distribution of other components is used. The
result show that the assumption is valid as the flow of light non-key at bottom and
heavy non-key at top is negligible.
Component
C4H10
C5H12
C10H8
Table VI.5.6: Distribution of non-key components:

Flow (kmol/h)
2.14E-12
4.11E-08
2.10E-11
85 | P a g e
Y.S.E. Soh
Column Diameter
Calculated column diameter: Top= 1.152 m, Bottom= 1.104 m
By rounding up the larger column diameter to the nearest standard head size,
design column diameter is 1.2192m (nominal pipe size 48 inches).
Calculated Pressure Drop
Total pressure drop of column= 0.47 bar
Estimated pressure drop of column= 0.50 bar
Difference between estimated and calculated pressure drop= 0.03 bar
Height of column
Upper and lower disengaging space= 3 m
Total height of column with disengaging space= 19.335 m
Height to diameter ratio= 15.86 (satisfactory as it is less than 20)
Hydraulics Design and Comparisons with HYSYS
Table VI.5.7: Comparison for hydraulics design
Aspect
Column diameter, m
Column height, m
Column area, m2
Downcomer area, m2
Net area, m2
Active area, m2
Hole area, m2
Weir length, m
Hole pitch, mm
Weir height, mm
Hole diameter, mm
Plate thickness, mm
Manual
Calculation
1.2192
19.335
1.1675
0.0759
1.0916
1.0157
0.0660
0.7803
15.500
50.000
5.0000
5.0000
HYSYS
Simulation
1.2190
15.000
1.1670
0.1054
1.0616
0.9566
0.0598
0.8606
15.500
50.000
5.0000
5.0000
Error (%)
0.02
28.7
0.04
27.9
2.83
6.18
10.4
9.33
-
There is a significance difference in calculated column height and HYSYS-simulated

column height. This might be due to the addition of top and bottom disengaging
space to the calculated column height. Besides, the downcomer area in simulation
is about 28% greater than the calculated downcomer area. The difference is likely
to be caused by the assumption of downcomer area to be 6.5% of column area in
manual calculation. Errors in active area and hole area are caused by the difference
in downcomer area. Nevertheless, calculated weir length differs from the simulation
because graphical method is used in determining the weir length for manual
calculation.
Selection of Construction Material
Carbon steel (A285 Grade A) is used as construction material as operating
temperature is well below the maximum temperature of material (482 oC) and
pressure of column is relatively low. Moreover, carbon steel can be used as system
is non-corrosive.
86 | P a g e
Y.S.E. Soh

Equipment Type
Item Code
Service
Author
Drawing number
Distillation Column
DC-103
Soh Yi Shin Elaine (013332)
Appendix AIV.VI.5
D-DC103
Design Data
Design Pressure
Operating Pressure
Overhead Pressure
Bottom Pressure
Bottom Temperature
Feed Flow Rate
Feed Temperature
2.53
1.80
1.80
2.30
97.4
164.2
9739.3
113.0
bar
bar
bar
bar
o
C
o
C
kg/h
o
C
Number of trays
Feed Tray Location
Reflux Ratio
Column Diameter
Column Height
Liquid Flow Pattern
Condenser Type
Reboiler Type
Type of Tray
Tray Spacing
Tray Thickness
Column Area
Downcomer Area
Net Area
Active Area
Hole Area
Weir Length
Weir Height
Hole Diameter
Hole Pitch
Downcomer Backup
28
17
0.986
1.2192
19.335
0.50
Single Pass
Total
Partial
Hydraulics Design
Sieve tray
Carbon steel
0.600
5.000
1.167
0.076
1.092
1.016
0.066
0.780
50.00
5.000
15.50
3363
248.0
m
m
bar
-
m
mm
m2
m2
m2
m2
m2
m
mm
mm
mm
mm
87 | P a g e
Y.S.E. Soh
Equipment Drawing for DC-103
88 | P a g e
VI.6 General Arrangement Drawing
89 | P a g e
VI.7 List of Equipment and Load Sheet

Adsorber
DH-101
DH-102
PSA-101
PSA-102
PSA-103
PSA-104
Compressors
C-101
C-102
C-103
Crystalliser
CR-101
Drums
RD-101
RD-102
RD-103
RD-104
RD-105
FV-101
FV-102
Furnaces
F-101
F-102
Heat Exchanger
HE-101
HE-102
HE-103
HE-104
HE-105
HE-106
HE-107
HE-108
HE-109
HE-110
HE-111
HE-112
HE-113
HE-114
HE-115
HE-116
HE-117
Membrane Unit
MR-101
Pumps
P-101
P-102
P-103
P-104
P-105
P-106
P-107
P-108
Reactors
RX-101
RX-102
Reboiler
RB-101
RB-102
RB-103
RB-104
RB-105
Towers
DC-101
DC-102
DC-103
DC-104
SC-101
ST-102
Turbine
TB-101
Dehydrator Vessel 1
Dehydrator Vessel 2
PSA Adsorbent Bed 1
PSA Adsorbent Bed 2
PSA Adsorbent Bed 3
PSA Adsorbent Bed 4
Lead Engineer
Arati Banu
Arati Banu
Joel Chan
Joel Chan
Joel Chan
Joel Chan
Product Compressor 1
FideliaPrasetya
Fidelia Prasetya
Fidelia Prasetya
Naphthalene Crystalliser
Joel Chan
Reflux Drum 1
Reflux Drum 2
Reflux Drum 3
Reflux Drum 4
Reflux Drum 5
Feed Flash
Product Flash
Elaine Soh
Elaine Soh
Fidelia Prasetya
Fidelia Prasetya
Kim Tae Yeon
Arati Banu
Joel Chan
Feed Heater
Recycled Stream Heater
Fidelia Prasetya
Elaine Soh
Feed Cooler
Feed Heater
Absorber Inlet Heater
DC-101 Feed Heater
ST-101 Solvent Heater
Recycled Solvent Cooler
Feed Preheater
Compressor 1 Inlet Cooler
Flash 2 Inlet Pre-Cooler
Product Heat Exchanger
Product Preheater 1
Product Preheater 2
Product Heater
Toluene Cooler
Flash 2 Inlet Cooler
Arati Banu
Kim Tae Yeon
Elaine Soh
Kim Tae Yeon
Kim Tae Yeon
Arati Banu
Joel Chan
Elaine Soh
Kim Tae Yeon
Elaine Soh
Kim Tae Yeon
Arati Banu
Arati Banu
Elaine Soh
Kim Tae Yeon
Elaine Soh
Kim Tae Yeon
Arati Banu
Reflux Pump 1
ST-101 Feed Pump
Fresh MEA Solvent Pump
Reflux Pump 2
Recycle MEA Solvent Pump
Reflux Pump 3
Reflux Pump 4
Reflux Pump 5
Elaine Soh
Fidelia Prasetya
Kim Tae Yeon
Kim Tae Yeon
Kim Tae Yeon
Fidelia Prasetya
Elaine Soh
Fidelia Prasetya
Packed Bed Reactor

Packed Bed Reactor
Joel Chan
Joel Chan
Reboiler
Reboiler
Reboiler
Reboiler
Reboiler
Arati Banu
Kim Tae Yeon
Fidelia Prasetya
Elaine Soh
Fidelia Prasetya
1
2
3
4
5
Propane Distillation Column

Product Purifying Distillation Column
Benzene Distillation Column
Naphthalene Distillation Column
CO2 Absorber
MEA Solvent Regenerator
Arati Banu
Fidelia Prasetya
Elaine Soh
Fidelia Prasetya
Kim Tae Yeon
Kim Tae Yeon
Feed Turbine
Fidelia Prasetya
90 | P a g e
VESSEL SPECIFICATION SHEET

Project Title: Benzene Production
Date:
Compiled by:
A.Banu
Item No.
FV-101
17/4/16
DH-101
Checked by:
PSA-101
G-Force
RD-103
Item Description
Flash Drum
Dehydrator
Pressure Swing
Reflux Drum
20.0
19.7
48.5
3.2
22
21.67
53.35
3.52
1.98
9.82
0.70
3.51
Ellip.
0.008
Ellip.
0.008
8
18
8
18
CS
CS
30.0
30.0
60.7
60.4
Design Conditions
27
27
66.77
66.77
Shell
1.22
1.22
6.44
6.40
Heads
Ellip.
Ellip.
0.008
0.008
Connections
0.2
8
0.46
18
Materials
SS-304
SS-304
Temperature, C
Pressure, bar
Temperature, oC
Pressure, bar
Diameter, m
Height, m
Type
Minimum Head, m
Nozzles size, m
Manhole diameter, m
Shell & Heads
COMPRESSOR SPECIFICATION SHEET

Project Title: Benzene Product
ion
Item No.
Date:
17/4/16
Item Description
3
Normal Flow, m /h
Design Flow, m3/h
Suction Pressure, bar
Discharge Pressure, bar
Normal Temperature, oC
Design Temperature, oC
Isentropic Efficiency, %
Speed (rpm)
Compiled by:
Checked by:
C-101
A.Banu
G-Force
C-102
Compressor
Compressor
Performance
303.1
333.41
1.1
7.8
44.97
49.47
70
1800
Carbon Steel
303.1
333.41
7.6
20.2
79.89
87.88
70
1800
Carbon Steel
91 | P a g e
COLUMN SPECIFICATION SHEET

Project Title:
Date: 17/4/1
6
Benzene Production
Item #
Item Description
Column
Internal Diameter, m
Wall Thickness, m
Height, m
Packing Height. m
Packing Type
Compiled by:
A.Banu
Checked by:
SKETCH
G-Force
ST-101
Stripper
2.33
0.05
12
9.6
Ceramic Intalox
Design Pressure, bar

Fluid:
Phase (V,L,V/L)
Feed Temperature, oC
Ovhd Temperature, oC
Btms Temperature, oC
Ovhd Pressure, bar
Btms Pressure, bar
Liquid Feed
Vapor Product
D =10 ft
4.0
Carbon Steel
V/L
269
20.0
269.0
2.5
4.0
HETP = 24 in.
Packing = 40 ft
T-T H = 50 ft
Vapor Feed
Liquid Product
HEAT EXCHANGER SPECIFICATION SHEET

Compiled by: A.Banu
Date:
17/4/16
HE-109
Project Title: Benzene Production

Item #
HE-107
Item Description
Heat Exchanger
Checked by: G-Force

HE-102
Cooler
CD-101
Condenser
Heater
Exchanger Side
SS
Fluid Circulating
S-52
S-39
Cooling Wat
er
S-01
S-06
Low Pressure
Steam
S-12
Cooling Wat
er
3.8
38
180
20.6
190
164
3.0
25
52.0
3.0
152.0
58.0
15.0
43.9
43.9
1.01
7
25
Process Conditions
Pressure, bar
Inlet Temp C
Outlet Temp, C
Performance
Heat Duty (kW)
Overall Coeff. (W/m2C)
Log Mean T (C)
Surface Area (m)
2215.96
50
45.76
58.59
60.1
30
87.7
3
133.5
103.5
7398.34
50
699
300
356.3
300
64.41
382.90
58.56
28.10
26.9
8.8 x 10-5
92 | P a g e
VI.8 Scheduling of Equipment (Pump)
Equipment
Number
P-103
Operating
Media Characteristic Condition
Liquid
Type: Temperature:
Newtonian Fluid
97.4C
Flowable
Compositional
Viscosity: 6.01E-04 Flowrate:
Pa.s
2333.86 m3 /h
pH: 7
Type
Screw/Positive
Displacement
(PD)
Suction
Discharge
Condition Head
Pump Specification
NPSH:
281.38 m
Head
loss: 0.05
m
Pressure: 1.8
bar
Theoretical Power
Required: 865.79 W
Actual Power
Required: 1331.98
Efficiency: 65%
Piping
Material: Carbon Steel

Piping Diameter:
0.2032 m/8 inches
S.G.: 0.0035
Equipment
Number
P-108
Operating
Media Characteristic Condition
Liquid
Type: Temperature:
Newtonian Fluid
90.3C
Flowable
Compositional
Viscosity: 5.64E-04 Flowrate:
Pa.s
125.16 m3 /h
pH: 7
Pressure: 1.5
bar
S.G.: 0.0040
Type
Screw/Positive
Displacement
(PD)
Suction
Discharge
Condition Head
Pump Specification
NPSH:
233.14 m
Head
loss: 0.05
m
Theoretical Power
Required: 717.37 W
Actual Power
Required: 1103.64
Efficiency: 65%
Piping
Material: Carbon Steel

Piping Diameter:
0.2032 m/8 inches
93 | P a g e
Section VII. Environmental Protection

MODULE CODE
GROUP
GA SUPERVISOR
ACADEMIC SUPERVISOR
DATE OF SUBMISSION
AUTHORS
Group member:
NAME
Fidelia Prasetya
Kim Tae Yeon
Soh Yi Shin Elaine
H83DPX
4
Dr. Sara Kazemi Yazdi
Prof. Dominic Foo
Mr. Rafil
18th April 2016
CHAN JOEL KAI CHIN
011032
STUDENT ID
013802
011494
013461
013332
PROGRAMME

Selangor, Malaysia
G | Page
VII. Environmental Protection

VII.1 Introduction (Environmental Management)
It is important for the interest of stakeholders to protect, conserve and sustain
the fragile and priceless environment while making consistent and sustainable
profit. Most modern chemical plants exercise a strict environmental
management in order to steer the development process to take advantage of
environmental opportunities, avoid hazards, mitigate ensuing environmental
problems and prepare people for unavoidable difficulties by improving
adaptability and resilience (King, 2005).
Firstly, it is crucial for any environmental management planning to identify all
streams for possible emission, leakage and spills to the environment by
highlighting them in the PFD. Therefore, Environmental Impact Assessment
(EIA) is adapted as an effective tool to analyse and describe all the sources
hierarchical as listed in the PFD in terms of the state/phase, source,
consequences and suggested mitigating action or implementation. Moreover,
after completing the EIA, a Leopold Matrix will be proposed to rank all the
involved streams in terms of the severity & lasting period.
Through the EIA process, streams that can be mitigated are further narrowed
down, the selected streams will be managed, handled, treated or disposed
in the best suited manner. Several appropriate methods from reliable sources will
be suggested to manage, handle, treat or dispose the waste products. For
certain products that are designated to be treated in a waste product
treatment plant, an elementary mass balance calculation and simple PFD
are made for the treatment plant so that the exiting effluents adheres to
local environmental legislations.
Adhering to local environmental legislations is also important so that the plant
will not be penalized for environmental irregularities or penalty. This section will
cover two types of legislations, the first is the air pollution control legislation
and the second is the surface water discharge legislation. All of the
components in the exiting effluents will be shown whether they exceed the
allowable limits and if not what final measures or steps are taken to satisfy the
requirement.
Finally, a review will be made on certain integrations made for cleaner
production strategies so that the chemical processes can be made greener
and sustainable. It is important that chemical products are deemed benign and
safe to the environment so that the products satisfy ISO standards and other
environmental accreditations which allow more market opportunity in developed
countries.
94 | P a g e
VII.2: Identification of Emission Stream & Possible Emission, Leakage & Spill in PFD
Figure 9.2.1: Process Flow Diagram with Labelled Effluent Streams

=
Environmental
ByProducts
= Economical Products
95 | P a g e
VII.3 Environmental Impact Assessment (EIA) & Leopold Matrix

VII.3.1 Environmental Impact Assessment (EIA)
A deliberate and thorough analysis is followed up for all of the identified effluent streams in the PFD by listing down
the possible sources of emission resulting from (land, air or water) direct release, leakage or spillage for each
highlighted stream. On top of that, after determining the possible sources of emission for each stream, the impacts
resulting from each possible emission are listed out in terms of the contaminating effects to the environment .
Therefore, by identifying the impacts resulting from the possible sources of contamination found out in this
assessment, the appropriate mitigating actions are further suggested to overcome them.
Table VII.3 Environmental Impact Assessment (EIA)
Stream No.
Possible
Emission
(Source)
Medium
Environmental Impact
Contaminate
d
Environmental By-Products
Stream-05
1) Direct Emission
to Tarim River
(Point Source)
2) Spillage (NonPoint Source)
3) Leakage (NPS)
4) Washing
/Maintenance
(NPS)
1) Water
2) Soil
3) Air
Main Compone
nts:
1) CnH2n+2
(n=1 to 5)
2) H20
1) Poison and toxic potent if

mixed in drinking water
(Levi, 1997)
2) Highly volatile nature causes
diffusion into atmosphere and
may contribute to photochemical smog
(Jack G Calvert, 2008)
3) Two immiscible layers formed
block O2 gases dissolving into
the river (Dissolved Oxygen
level decreases)
4) Aquatic animals found in the
river will die due to reduce DO
levels and also the
accumulation of toxic aliphatic
hydrocarbons in targeted
organs
Mitigating Actions
1) Send wastewater to a
built-in treatment plant
2) Ensure spillage and leakage
are adequately avoided by
designing a reliable process
control design that ensures
related valves function
accordingly
3) Continuous chemical
monitoring should be done
4) Ensure maintenance of
pipelines, valves and
equipment are done
periodically
96 | P a g e
Stream-19
Main Compone
nts:
1)
CnH2n+2
(n=3 to 5)
Stream-62
Main Compone
nts:
1)
2)
3)
4)
C5H12
C6H6
C10H8
C7H8
Stream-87
Main Compone
nts:
1) CnH2n+2
(n=1 to 5)
1) Direct Emission
to local air (PS)
2) Leakage (NPS)
3) Cleaning/
Maintenance
(NPS)
1) Air
2) Soil
3) Water
1) Neurological suppressant effect

at moderate concentration but
at high concentration may lead
to death if inhaled directly
(Levi, 1997)
2) Highly volatile nature causes
VOC diffusion into atmosphere
and may contribute to photochemical smog when mixed
with nitrous oxide (NOx gases)
(Jack G Calvert, 2008)
3) Reducing visibility range due
to presence of photochemical
smog
1) Recycled as fuel
gases that will be used
as fuel in reactor-101 for
heating purposes
2), 3) & 4) same as previous
suggested mitigating
1) Direct Emission
to local air (PS)
2) Leakage (NPS)
3) Cleaning/
Maintenance
(NPS)
1) Air
2) Soil
3) Water
1) Recycled as fuel
gases that will be used
as fuel in reactor-101 for
heating purposes
actions
1) Direct Emission
to local air (PS)
2) Leakage (NPS)
3) Cleaning/
Maintenance
(NPS)
1) Air
2) Soil
3) Water
1) Contributing to photochemical
smog (similar to stream-19)
2) Benzene vapour is carcinogenic
which leads to leukemia
(Levi, 1997)
3) Toluene vapour may lead to
dizziness and nausea but at
high concentration may cause
coma or death (Levi, 1997)
4) Aromatic products which are
toxic may destroy surrounding
plants by causing chlorosis and
accumulate at target organs in
animals
smog ( similar to stream-19)
2) Benzene and toluene effects
(similar to stream-64)
3) Aromatic products affecting
the environment (similar to
stream-64)
1) Controlled ignition
combustion
to avoid hydrogen
explosion in the thermal
oxidizer
97 | P a g e
2)
3)
4)
5)
C6H6
C10H8
C7H8
H2

actions
Economical Products
Stream-14
Main Compone
nts:
1) Leakage (NPS)
2) Cleaning/
Maintenance
(NPS)
1) Air
2) Water

smog ( similar to stream-19)
and thus reducing visibility
range
1) Proper storage of
propane in pressurized
cylinders that will be
sold
actions
1) Direct Emission
to local air (PS)
2) Leakage (NPS)
3) Cleaning/
Maintenance
(NPS)
1) Air
2) Water
3) Soil
1) CO2 contributes significantly to

greenhouse effect and
subsequently global warming
2) MEA vapour will dissolve in
rain water and enter into the
soil and also near-by water
sources
3) MEA causes chemical burns
but at high concentration it will
1) Sold to neighbouring
plant for industrial usage
2) Recycled as an
extinguishing medium
for RX-101 at the
combustion shell side
1) Spillage (NPS)
2) Leakage (NPS)
3) Cleaning/
Maintenance
(NPS)
1) Water
2) Soil
3) Air
1) C3H8
2) C4H10
Stream-30
Main Compone
nts:
1) CO2
2) MEA
Stream-72
Main Compone
nts:
1)C5H12
2) C6H6
3) C7H8
cause kidney and liver damage

2) Benzene health effects
3) Spillage/leakage will lead to
toxicity and reduced DO levels
which will affect the population
of aquatic animals (similar to
stream-05)
benzene in internal
floating roof vessels at
safe and risk free
condition
(Slke, 2008-2016)
2) Design of storage vessels
incorporate containment
basin which can hold up
10% or more product
spillage
98 | P a g e

actions
Stream-82
Main Compone
nts:
1) Spillage (NPS)
2) Cleaning/
Maintenance
(NPS)
1) Soil
2) Air
3) Water
1) C10H8
2) C7H8
Stream-84
Main Compone
nts:
1) Spillage (NPS)
2) Leakage (NPS)
3) Cleaning/
Maintenance
(NPS)
1) Water
2) Air
3) Soil
1) Leakage (NPS)
2) Cleaning/
Maintenance
(NPS)
1) Air
1) C6H6
2) C10H8
3) C7H8
Stream-86
Main Compone
nts:
and thus reducing visibility
range
2) Naphthalene is able to cause
cataract, retinal haemorrhage
& haemolytic anaemia at long
exposures (EPA, 2016)
3) Moderately toxic to fishes and
certain aquatic animals
2) Toluene health effects
3) Spillage/leakage will lead to
toxicity and reduced DO levels
which will affect the population
of aquatic animals (similar to
stream-05)
2) Highly explosive when mixed
with air
naphthalene in an
enclosed container to
prevent dust explosion
actions
naphthalene in an
enclosed container
actions
1) Transported to another
neighbouring plant
actions
1) N2
2) H2
99 | P a g e
VII.3.2 Leopold Matrix

The Leopold Matrix is utilized to rank all of the streams in terms of
envisaged (predicted) environmental factors for 3 main groups which are (i)
Physical, (ii) Biological & (iii) Social where further specific sub-groups are
assigned to each of them. This is because, each stream that has accompanying
environmental impacts can be physically manifested in each environmental
group factor and the severity may deviate individually. After listing the severity
of each stream for each envisaged environmental factor with the scale of 1-5 at
which value 1 represents very mild effect and value 5 represents very severe
effect; the different shades of purple for each box represents the different active
period before it completely loses the damaging strength. The template of this
matrix was modified from a primordial version taken from (Bosko Josimovic,
2014).
VII.3.2.1 Findings from Leopold Matrix
Table VII.3.2.1.1: Top 5 Environmental Damaging Streams & Top 5 Most Effected
Environmental Factor
Environmental Damaging Str Most Effected Environmental Factor
eams
1) Stream-72 & 84
Physical (Air): Air Quality
2) Stream-05
Social (Land Uses): Recreational Activities
3) Stream-82
Biological (Flora): Forest, Biological (Flora):

Crops, Social (Land Uses): Fisheries
4) Stream-62
Social (Society): Hazards
5) Stream-19
Physical (Soil): Soil Quality, Biological (Fau

na): Fishes
VII.3.2.2 Leopold Matrix Table

(Refer to Appendix: VII.3.2.2)
VII.4: Managing, Handling, Treating & Disposal of Waste Products
VII.4.1: Waste Streams Channelled to Wastewater Treatment Plant
As suggested in the EIA analysis, only stream-05 is channelled to a built-in
waste water treatment plant because only this stream exist in aqueous phase
and that it contains large amounts of CnH2n+2 (n= 1-5) and mainly H2O.
Therefore, it is necessary to design a waste water treatment plant that is
able to separate effectively the aliphatic hydrocarbons from the bulk
water before it is being released to the nearest source of water which is the
Tarim River (Refer to Section VII.5). Precautions have to be taken to ensure that
the final treated water adheres to the local surface water discharge legislation
(Refer to Section VII.5).
This part will further be covered in Section 9.5: Basic Wastewater
100 | P a g e
Discharge Treatment Plant where a simple process flow diagram will be

shown to provide the reader an understanding of the unit operators and
processes involved. On top of that, simple mass balance calculations are
provided so that sizing of the unit operators can be performed
VII.4.2 Waste Streams Disposed by Thermal Oxidizers
From the EIA analysis, only stream-87 is suggested to be combusted
safely due to the presence of some fraction of hydrogen. Therefore it cannot be
used as a recycle residual gas to heat up reactor-101. Instead, stream-87 is
suggested to undergo high precision incineration in a thermal oxidizer (TO)
due to the explosive nature of hydrogen gases. (C. David Copper, 2014).
Currently, the more developed and efficient regenerative thermal oxidizers (RTO)
has replaced the predecessor, RTO is claimed to recover up to 97% of the
thermal energy in the exiting flue gas (C. David Copper, 2014). Thus, RTO is
the best suited unit operator to safely dispose stream-87 in a controlled
manner and where heat energy can be safely recovered.
RTOs utilizes two chambers packed with ceramic transfer mediums where
the heated ceramics pre-heat the cool entering stream-87 so that they are
partially oxidized before complete oxidation occurs in the thermal oxidizer
section (C. David Copper, 2014). RTO is also able to withstand the
controlled explosive nature of hydrogen gases due to the utilization of
ceramic chambers .Thus, due to the complexity of the design and sizing of the
RTO unit, the sizing calculations will not be covered in this report.
VII.4.3 Disposal of Deactivated MO/HZSM5 catalyst
No data can be found on the lifetime of MO/HZSM-5 catalyst before it
deactivates, however assuming that the catalyst can no longer be regenerated,
all of the catalyst pellets will be saturated with the various VOCs that pass
through them. Since, the base of the catalyst are made of alumina which is
considered ceramic, therefore to incinerate them is difficult due the high melting
point nature. The only way to effectively handle them is to store them in steel
barrels and transport them to a landfill. Therefore, third party sources are
acquired to transport and safely dispose them in landfills.
VII.4.4 Storing & Handling of CO2
(Refer to Section VII.7.2)
VII.4.5 Waste Stream Recycled as Fuel Gases for RX-101
VII.4.6 Purified Hydrogen Gas Handling & Disposal
101 | P a g e
VII.5: Basic Waste Effluent Treatment Plant Design

VII.5.1: Brief Introduction of Engineering Challenge and Approach for
Solution
The purpose of the in-house built wastewater treatment plant is to treat
wastewater that originates from 2 main sources which are:
(i) Stream-05 that contains mainly water and other hydrocarbon component,
CnH2n+2 (n=1-5),
(ii) Water that is contaminated from products that originates from scenarios such
as
leakage or spillage in the storage tanks of final aromatic products during
maintenance . Washing of storage tanks and equipment during plant
shutdown.
According to (Vidali, 2001), biological methods or bioremediation
processes are economical, energy efficient and environmentally sustainable to
treat VOC & monoaromatic products. Therefore the design of an ex-situ
bioremediation process that utilizes bioreactors and other auxiliary equipment
required to remove the VOC & monoaromatic components.
VII.5.2: Basic Process Flow Diagram (PFD) of a Bioremediation Wastewater
Treatment Plant
Figure VII.4.2.1 Process Flow Diagram of the Proposed Wastewater Treatment Plant
102 | P a g e
Table VII.5.2.1: Description of Activity Sequences according to PFD

Sequence
Unit Operati
on
Storage Tan
k (ST-101)
Activity
Description
(i) Stream Storing

and Channelling
2)
Bioreactors
(BR-101 & 1
02)
(i)
(i) Inlet stream, F1 is stored in t

he equalizing tank when both bio
reactors are being utilized
(i) PH level, temperature, conduc
tivity and other important param
eters are adjusted
(ii) Pseudomonas Putida (Van Ha
mme, 2003) is mixed together w
ith the wastewater and used an
aerobic decomposition agent
(iii) Mixture is stored for another
10-12 hours for the microbial ac
tivities (Ohlen, 2005). VOC remo
val efficiency of 98% (Ohlen, 20
05)
3)
Clarifier
(CL-101)
(i) Artificial Aeration

(ii) Skimming
(iii)Recycling of
Settled Activated
Sludge (biomass)
(i) Air bubbles are introduced int

o the MMLS mixture in the clarifi
er tank. Air bubbles will bind tog
ether with small flocs of suspend
ed solids (SS) causing the densit
y of such SS < density of water.
(ii) A mechanical skimmer is use
d to remove the floating suspend
ed solids which floats on water.
(iii) Settled activated sludge (bio
mass) is recycled back to the bio
reactors at 60% recycling value.
4)
Ultrafiltratio
n Membrane
Unit
(MR-102)
(i) Filtration
(i) Stream F10 is filtered to rem

ove the remaining dissolved susp
ended solids at 99% efficiency.
1)
Mixture
Conditioning
(ii) Microbial Seeding
(iii)Microbial Activity
(Decomposition)
VII.5.3 Basic Mass Balance Calculation & Sizing of Wastewater

Treatment Plant Sizing
VII.5.3.1 Mass Balance and Sizing for Bioreactors (BR-101 & 102):
Mass Balance
Assumptions:
1) Bioreactors are modelled after Monod equation for biomass growth
2) Hydraulic retention time (HRT) =12 hours, therefore in day, there
will be two continuous batches
3) Percentage of VOC decomposition by Pseudomonas Putida seeding= 98 %
(Ohlen, 2005)
103 | P a g e
4) Bioreactor-101 & 102 have the same working capacity

5) Seeding and biomass generated does not contribute to overall volumetric flow
6) Streams in BR-102 such as F6, F7 and F8 is the same as F2, F3 and F5 in BR101
(Calculations and mass balance table refer to appendix section VII.4.3.1)
Bioreactor Sizing
(Calculations refer to appendix section 9.4.3.1)
Actual Volume of bioreactor (each) = 0.7016 m3
Taking into consideration of overfilling factor in BR-101 & 102
Sized Volume of bioreactor (each) = 1 m3
VII.5.3.2 Mass Balance for Secondary Clarifier (CR-101):
Mass Balance
Assumptions: 1) Percentage of Recycled Biomass= 60%
2) Percentage of retained H2O in Biomass= 20%
3) During batch operation in BR-101 or BR-102, the clarifier only
receives one outlet stream from a reactor, thus F3=F4=F7
VII.5.3.3 Mass Balance for Ultrafiltration Membrane (MR-102):
Mass Balance
Assumptions: 1) Ultrafiltration Membrane Efficiency = 99%
VII.6: Review & Adhering to Local Environmental Legislation
VII.6.1 Local Ambient Air Quality Standards
The local ambient air quality standards are taken from the Ambient Quality
Standards, GB 3095-2012 by the Ministry of Environmental Protection China.
Only stream 87 which is channeled to a thermal oxidizer (incinerator) produces
flue gas emitted to the environment. Moreover, scrubber and air filter units are
utilized to trap the particulate matters formed from combustion process. The
allowable concentrations follow the first area group in the standards which is
falls on the natural reserves and scenic spots which has special protection
status.
(Refer to Table VII.6.1.1 in appendix section for Local Ambient Air Quality
Standards (GB 3095-2012))
Findings: It was found from table VII.6.2.1 that the all parameters are found in
trace amount with the exception of CO in exiting flue gas which is of
considerable concern but satisfies the allowable limit
104 | P a g e
VII.6.2 Environmental Quality for Surface Water Standards (GB 38382002)

The local surface water quality standards are taken from the Surface Water
Quality Standards, GB 3838-2002 the Ministry of Environmental Protection
China. The emission concentration are based on F11 stream (from Section
VII.5.3) in the wastewater treatment plant which will eventually be release to
the Tarim river. The allowable concentration follows the first area group which
falls on natural reserves and scenic spots which has special protection status.
(Refer to Table VII.6.2.1in appendix section for
Surface Water Standards (GB 3838-2002)
Environmental Quality for
Findings: It was found from table VII.6.2.1 that the all parameters are found in
trace amount with the exception of BOD5 with pH level for exiting water
effluent which is of considerable concern but satisfies the allowable limit
VII.7 Cleaner Production Strategies
Cleaner production strategies are becoming more important in chemical plants
due to the rise of sustainable and greener production requirements by EPA and
also Green Economy by the European Union Commission (European
Commission - Basics, 2016)The objective of this section is to prove that the
products can be sold in accordance to the trading laws and cleaner
production regulations established by western countries.
Most requirements require manufacturers to have regulated CO2 emission and
less energy demand usage. Therefore in this section, all by-products will be
innovatively converted to useful products or energy that can be reused in the
plant. Moreover, the plant is proposed to achieve ISO 14000-Environmental
Management System accreditation which is important to further widen the
market scope for the products.
VII.7.1 Less Carbon Soot Production by RX-101 with Membrane
Technology Integration for H2 Gas Removal
A cleaner production is implemented by proposing the usage of membrane
technology that removes H2 gases which drastically reduces the production of
carbon soot. Removing of H2 gases can drastically improve the efficiency of
higher aromatic chain conversion which results in lesser carbon soot production
due to the almost complete conversion of CH4 (Enrique Iglesia, 2002). Therefore,
less catalyst is required and the cleaning of the reactor is cleaner due to less
carbon soot production.
VII.7.2 Storing & Handling of CO2 through Selling of CO2 for Industrial
Usage Or Biogenic Capture Via Microalgae Cultivation in Open Pond
Stream 30 and other flue gases such as those that come from the burning of
recycled residual gases to heat up RX-101 are channeled to a neighbouring plant
for CO2 reprocessing and that it will be meant for industrial usage such as
ammonia production, fire extinguishing medium or even carbonation of soft
drinks.
105 | P a g e
Alternatively, CO2 can also be supplied to a microalgae pond that utilizes

photosynthesis mechanism to convert CO2 into other products. Biogenic capture
by using microalgae is effective in fixing CO2 from air and converting it into
glucose as food (C. David Copper, 2014). Moreover, according to (Sayre,
2010) it was found that CO2 capture efficiency by open ponds are as
effective as 90%. Moreover, almost all of the biomass in microalgae can be
harvested into biodiesel in regardless of harvesting seasons, unlike terrestrial
crops such as corn or soy beans plants where only the corn cob and soy bean
can be used for biodiesel production (Sayre, 2010). Since, microalgae grows
very fast and can be cultivated year long, microalgae is a viable
economic product for commercial production of biodiesel. The design
consideration and sizing calculations will not be covered in this section
VII.7.3 Waste Stream Recycled as Fuel for Heating of RX-101
As mentioned previously in the individual design portion of RX-101, streams 19
& 62 are recycled as residual gases which acts as fuel for the heating of RX101 due to endothermic nature. These streams are suggested to be use because
the temperature drop found from (Section VI.1.4.2) is quite small at 0.85C,
therefore small volumes of fuel are required . Combusted flue gases which
contains mainly of CO2, CO and some fraction of H2O vapour will be channeled to
the biogenic capture pond mentioned previously. However, only stream 19 is
considered in heat integration of overall heat utility (refer to section V: Energy
Recovery & Utilities)
VII.7.4 Supply of Purified Hydrogen Gas to a Neighbouring Plant for
Commercial Hydrogen Gas
Stream 86 which consist of 99% purity hydrogen gas will be supplied to a
neighboring plants that processes hydrogen gas into compressed cylinders for
commercial purposes. This proves that the hydrogen gas which was formerly a
by-product is deliberately purified to reduce wastage and increases plant
profitability.
VII.8 Conclusion
In a nutshell, environmental protection is crucial to ensure that the operation of
this plant in the Tarim basin does not cause irreversible environmental damages
which may affect the livelihood of communities established in this area. It is of
upmost important that environmental precautions are covered in all aspects to
minimize the environmental impacts that may be contributed. Moreover, since so
many environmental strategies and mitigating actions that have been outlined; it
is crucial that these measures are taken seriously during the operation of this
plant. One of the chief objectives that was achieved in this section is to ensure
that the operation of this plant is environmentally sustainable and benign in
order to preserve and conserve a clean environment for the future generations.
106 | P a g e
Section VIII. Process Safety

MODULE CODE
GROUP
GA SUPERVISOR
ACADEMIC SUPERVISOR
DATE OF SUBMISSION
H83DPX
4
Dr. Lam Hon Loong
Prof Dominic Foo
Mr. Rafil
18th APRIL 2016
AUTHORS:
Kim Taeyeon
Group members:
NAME
Soh Yi Shin Elaine
STUDENT ID
013802
013332
Chan Joel Kai Chin
011032
Fidelia Prasetya
011494
PROGRAMME
MEng Chemical with

Selangor, Malaysia
H | Page
VIII.1. Introduction
Mishandling of the chemicals or improper operation of the process in a plant can
cause many problems. They can evolve the casualties, the environmental issues
and the damages of plant itself let alone its business.
In this plant, the raw materials are hydrocarbons and the products are benzene,
naphthalene and toluene. They are all highly flammable and some of them are
toxic for long-term exposure. Moreover, the reaction occurs at high temperature.
These factors can cause severe problems such as explosion. The problems
damage personnel, plant and environment badly.
None of the plants can run away from the possibilities of the release of the
hazards. However, safety features can be designed avoid the worst case.
Therefore, in this section, safety studies will be reported to ensure the possible
hazards, risks, safety considerations and the appropriate measures.
VIII.2. HAZARD & OPERABILITY STUDY (HAZOP)
HAZOP table is a common mean to describe the potential safety issues and their
possible measures. In this study, the process is divided into the different
sections depending on the design intention of each of the equipment. The
potential risks of each stream in a section are then studied with possible
measures. The detailed tables are illustrated in Appendix.
Referring to HAZOP table in the Appendix, it was clear that the most frequent
hazard is related to flow, pressure and temperature. It is chiefly due to the
vapour feeds which are flammable and hazardous. For the feeds are vapours,
the delivery channels are piping lines. It means that the prior safety
consideration of the process is to monitor the pipe lines frequently and inspect
any leakage of the dangerous vapours customarily.
As what is seen from Appendix, below shows the primary safety risks stated with
bracket with numbers in, the potential sources of the risks expressed by capital
letters, the possible causes of the central risks by Roman numerals and the
specific streams of the particular causes by small letters.
(1)
Explosion
A. Scrubber
B. Distillation columns
C. Reactor
i.
High temperature reaching auto-ignition point
a. Streams after heat exchangers
b. Streams after furnaces
ii.
Ignition from the leakage
a. Any streams
iii.
Overpressure in the vessels
iv.
Increase in levels of the vessels
(2)
Ignition of the flammable gases due to leakage
A. Any streams
B. Any equipment
i.
Rupture of piping lines
107 | P a g e
ii.
Not correctly fitted valves
iii.
Not correctly fitted nozzles
iv.
Overfill of storage tanks
(3)
Overpressures
A. Any streams
i.
Blockage of the piping lines
(4)
Higher temperatures than operating condition
A. Overheating
i.
Slower flowrate of cooling agents than expected
B. Streams after furnaces
i.
Faster flowrate of fuels than expected
C. Distillation columns
i.
Reboiler/condenser failures
The two safety issues can be prevented with correct safeguards or minimized the
effects by proper and immediate action provided adequately according to the
equipment and piping lines. Risk parameters such as flow, temperature and
pressures are able to be monitored and regulated by installing the befitting
detectors, alarms and control valves. The detailed safeguards and actions are
demonstrated in HAZOP tables in the Appendix.
VIII.3. Emergency Response (Evacuation) Plan
Objective
Emergency response plan (ERP) minimizes the further loss/injuries of the
personnel. This also provides a manual to the personnel to follow in order to
protect the environment and themselves from the health threats. The
emergency procedures for the chemical leaks or spills and fire contain the
following steps.
(1)
Pre-emergency plan
A. Hazard identification
It is the identification of all potential on-site and off-site hazardous
operations. Its the information of toxic chemicals and all the physical
and chemical properties of the chemicals being handled. Mitigation plan
is developed to reduce the exposure to social/local communities or
environment when the events occur.
B. Risk analysis
It is the determination of the risk related to the hazard. Followings are
the steps
i.
Identification of potential failures
ii.
Estimation of the amount of chemicals for each failures
iii.
Evaluation of the consequences based on scenarios
These together enable the evaluation of the hazards according to the
locations and determine the zones of the frequent risks.
C. Legislation and standards
It is the identification of the regional regulations on environment,
health and safety and operational considerations.
D. Emergency organization and responsibilities
It transits normal operations to emergency operations. Also, it considers
108 | P a g e
the authority delegation from personnel operation to emergency

personnel.
E. Local assistance
Following are the sources of the emergency response resources
required to be identified.
i.
Fire station
ii.
Police offices
iii.
Regional agencies
iv.
Hospitals/doctors
v.
Nearest companies facilities
vi.
Help from alliance organizations
F. Internal alerting and external alerting
It is the internal communication between personnel and external
communication with emergency measure organizations.
(2)
Emergency response level spills
A. Response Action decision
It defines the emergency codes. Below, it shows the three levels of the
emergencies.
i.
Level 1: Leak/ minor fire
ii.
Level 2: Intermediate spill/fire
iii.
Level 3: Major spill/explosion
B. Plan activation
Emergency action checklist is needed to be first viewed to response
properly. It is as follows.
i.
Identification of emergency and casualties
ii.
Locate the source
iii.
Raise alarm
iv.
Isolate the hazards
v.
Personnel protection if necessary
vi.
Protection of resources
vii.
Activation of emergency communication
viii.
Further emergency assistance
ix.
Giving and receiving advice related to public affairs
x.
Rehabilitation
C. Response action/clean up
D. Emergency operation center
Emergency operation center must direct the response operations.
E. Evacuation
F. Disposal of spill and debris
G. Site restoration
H. Post-event evaluation
It helps to identify and improve the weakness from the previous
incidences.
(3)
Training and Drills
This is to train the personnel to give better understandings and practices
for future incidents.
(4)
Plan evaluation
It determines suitability of the emergency response plan.
(5)
Plan updates
109 | P a g e
Plant layout
Plant layout helps better understanding of the site and emergency exits.
Moreover, it is a map for the personnel to find the specific locations of the fire
extinguishers. On the other hand, it helps the emergency operation teams and
local firemen to find the place of fire/chemical spills or leak and to take the
immediate actions. Figure VIII.3.1. shows the plant layout.
Figure VIII.3.1.: Plant layout with emergency exits, assembly points and fire
extinguishers
VIII.4. Bow-Tie Diagram
Among many tools enabling the investigation and examination of the process
risks and safety, bowtie diagram is chosen for its conveniences. For example it
does not require numbers/orders at the same time it visualizes the logical
presentation.
Bowtie offers a visible guide-book for better safety of the plant. It visualizes the
prevention for the process safety conveniently and easily-understandably. It
represents the possible barriers to avoid the perilous and risky events. For
instance, it can encourage the safety team to monitor the correct vessels such
as reactor for the release of toxic and hazardous chemicals and the barriers such
as installing alarm for a prevention of particular event like explosion.
The most vulnerable events are examined and shown in the following figures;
VIII.4.1. VIII.4.4.
110 | P a g e
Figure VIII.4.1.: Bowtie diagram for explosion of scrubber
111 | P a g e
Figure VIII.4.2.: Bowtie diagram for explosion of reactor
112 | P a g e
Figure VIII.4.3.: Bowtie diagram for explosion of distillation columns
113 | P a g e
Figure VIII.4.4.: Bowtie diagram for explosion of storage tanks
114| P a g e
Section IX. Process Operation and Control

MODULE CODE
GROUP
GA SUPERVISOR
ACADEMIC SUPERVISOR
DATE OF SUBMISSION
H83DPX
4
Dr Ong Sze Pheng
Prof Dominic Foo
Mr. Rafil
18th APRIL 2016
AUTHORS:
SOH YI SHIN ELAINE (013332)
Group members:
NAME
Kim Tae Yeon
STUDENT ID
013802
013461
Chan Joel Kai Chin
011032
Fidelia Prasetya
011494
PROGRAMME
MEng Chemical with

Selangor, Malaysia
I | Page

IX.1: Executive Summary
Process control is essential to a plant as it ensures normal operation, product
quality within specification, plant safety and maximise the profits made. The
plant is designed to produce benzene as the main product with an annual
production of 64611.7 tonnes/year. Other side products such as propane,
hydrogen, toluene and naphthalene are also produced. The process can be
divided to three main sections; pre-treatment, reaction and separation. For pretreatment, the units involved are dehydrator, membrane unit and MEA scrubber.
Reaction section involves both the reactors whereas separation section is made
up of distillation columns, pressure swing adsorption unit (PSA) and crystalliser.
This section covers the process control for whole plant which includes general
plant start-up and shut down procedures, standard operating procedures (SOP)
as well as control strategies for different equipment.
A Piping and
Instrumentation diagram (P&ID) is drawn according to the control strategies.
IX.2: General Standard Operating Procedures (SOP) Manual
IX.2.1: Plant Prestart-up Safety Review
Table IX.2.1.1: Prestart-up safety review (PSSR) checklist
No
1
2
3
4
5
6
7
8
9
10
11
12
13
Actions
Tick if
applicable
Remarks
Reparation or replacement of equipment are

completed as instructed
All equipment pass inspection
Equipment and pipelines are flushed with
nitrogen to remove construction debris
Equipment are installed back on line as in P&ID
All required safeguarding check prior to start up
Pipelines and equipment undergo pressure test
to detect leakage
Sufficient human support (operators, process
engineer, maintenance officer, etc.) are available
for start-up
Changes made (equipment or pipelines) are
documented
New or modified equipment are inspected to
verify correct installation
Critical spare parts are available for start-up
All safety and emergency response equipment
are installed properly and function testing
completed
MSDS for different chemicals are available
All SOP are available and are updated according
to changes made
115 | P a g e

IX.2.2 General Plant Start-up Procedure
1.
2.
3.
4.
5.
6.
7.
Complete the prestart-up safety review (PSSR).

Ensure all drain valves are closed.
All equipment is de-spaded and air-free before start-up.
Start-up all the furnaces in plant.
Pre-heat reactor.
Start-up hot and cold utilities to all the units.
Introduce minimum amount of feed to plant once targeted temperature of
units are achieved.
8. Increase feed input to normal capacity of production.
IX.2.3 General Plant Normal Operation Guideline
1.
2.
3.
4.
5.
Operators in each shift should record data in logbook.

Held meeting before shift change to ensure effective communication.
Maintenance is carried out according to schedule.
All maintenance work should be well documented.
Collect samples from sample point regularly and conduct lab analysis to
determine the composition of sample.
6. Regular meeting among process engineer, operators and maintenance
coordinators.
IX.2.4 General Plant Shut Down Procedure
1.
2.
3.
4.
5.
6.
7.
Decrease feed input to plant gradually.

Decrease hot and cold utilities supplied to different unit.
Stop feed input to plant.
Stop hot utility.
Stop cold utility.
Depressurise and cool down unit.
Flush equipment and pipelines with nitrogen before opening up for
inspection and maintenance.
IX.2.5 Abnormal/Emergency Response

1. Refer to SOP of individual equipment for emergency response.
IX.3 Standard Operating Procedures (SOP) for Equipment

IX.3.1 Flash (FV-101 and FV-102)
Start-Up Procedures:
1.
2.
3.
4.
Set all controllers to manual mode.

Ensure drain valve, MV-101 (MV-106) is closed.
Open CV-102 to introduce feed to flash.
Open CV-103 (CV-147) and CV-104 (CV-148) to allow vapour and liquid
product to flow out.
5. Switch controller back to automatic mode.
116 | P a g e

Normal Operation:
1. Observe the pressure and level of column constantly to ensure normal
operation.
2. Flow and temperature of the inlet flow also need to be monitored to avoid
the separation of feed being affected.
Shut Down Procedures:
1. Set controllers to manual mode.
2. Gradually decrease the feed flow by adjusting CV-102 and shut it off
eventually.
3. Fully open CV-103 (CV-147) to depressurise column.
4. Fully open CV-104 (CV-148) to remove liquid in column.
5. Open MV-101 (MV-106) to remove the remaining liquid in the column and
to further depressurise the flash vessel.
Emergency Response:
Pressure Alarms
1. When PAH sounds, monitor the pressure profile of vessel closely.
2. If deviation persists, set the controllers to manual mode and increase the
opening CV-103 (CV-147).
3. When PAHH sounds, fully open CV-103 (CV-147).
4. If unresolved, emergency shut down of unit for inspection and
maintenance.
Level Alarms
1. When LAH or LAL sounds, monitor the level in flash closely.
2. If deviation persists, change controller to manual mode.
LAH: Increase the opening of CV-104 (CV-148).
LAL: Decrease the opening of CV-104 (CV-148).
3. If unresolved,
LAH: Open MV-101 (MV-106) to drain excess liquid.
LAL: Fully close CV-104 (CV-148).
IX.3.2 Dehydrator Column (DH-101 and DH-102)
*Note: Only one column will be operating at a time, the other column will be in
standby or regeneration mode.
Start-up Procedures:
1. Ensure MV-104 (MV-105) and MV-117 (MV-118) are closed before begin
start-up.
2. Set all the controllers to manual mode.
3. Close CV-105 (CV-106) to pressurise column and open MV-102 (MV-103).
4. Once, desired operating pressure (60.1 bar) is obtained, adjust the
opening of CV-105 (CV-106).
5. Once steady state is reached, change controller to automatic mode.
Normal Operation:
1. Monitor pressure of column constantly to ensure normal operation of
column.
117 | P a g e

2. Take sample of product outlet every 8 hours and perform analysis to
determine its composition.
Shut Down Procedure:
1. Change all the controllers to manual mode.
2. Gradually decrease the feed flow by adjusting CV-102 and shut it off
eventually.
3. Close MV-102 (MV-103).
4. Fully open CV-105 (CV-106) to depressurise column.
5. For regeneration of adsorbent (silica gel), open MV-117 (MV-118) to
introduce hot air to column.
6. Open MV-104 (MV-105) to drain water.
Emergency Response:
Pressure Alarms
1. When PAH sounds, monitor the pressure profile of column closely.
2. If deviation persists, change controllers to manual mode and increase the
opening of CV-105 (CV-106).
3. When PAHH sounds, fully open CV-105 (CV-106).
maintenance.
IX.3.3 Distillation Column (DC-101, ST-101, DC-102, DC-103 and DC104)
1. Set all controllers to manual mode.
2. Ensure drain valve MV-106 (MV-108, MV-112, MV-113, MV-114), distillate
valve CV-111 (CV-122, CV-151, CV-157, CV-162) and bottom product
valve CV-114 (CV-125, CV-154, CV-159, CV-165) are closed.
3. Fill reboiler with liquid product.
4. Open CV-110 (CV-121, CV-152, CV-156, CV-161) to introduce cold utility
to condenser.
5. Open CV-113 (CV-124, CV-153, CV-158, CV-164) to introduce hot utility.
6. Run the column at full reflux by opening CV-112 (CV-123, CV-150, CV-155,
CV-160) and activate pump, P-101 (P-104, P-106, P-107, P-108).
7. Introduce feed to column.
8. Once desired operating temperature and pressure is reached, adjust the
opening of reflux flow valve, CV-112 (CV-123, CV-150, CV-155, CV-160).
9. Open distillate valve, CV-111 (CV-122, CV-151, CV-157, CV-162) and
bottom valve, CV-114 (CV-125, CV-154, CV-159, CV-165).
10.Set all controllers to automatic mode once steady state is reached.
Normal Operation:
1. Monitor pressure, temperature and reflux ratio constantly.
2. Take sample of distillate and bottom product every 8 hours and perform
analysis to determine the composition.
118 | P a g e

2. Gradually reduce feed flow and adjust reflux valve CV-112 (CV-123, CV150, CV-155, CV-160) accordingly.
3. Stop feed flow to column.
4. Close CV-113 (CV-124, CV-153, CV-158, CV-164) to stop heating utility.
5. Close CV-111 (CV-122, CV-151, CV-157, CV-162) and CV-114 (CV-125,
CV-154, CV-159, CV-165) to stop distillate and bottom flow.
6. Stop cold utility by closing CV-110 (CV-121, CV-152, CV-156, CV-161).
7. Open MV-106 (MV-108, MV-112, MV-113, MV-114) to drain liquid from
column.
Emergency Response:
Temperature Alarms
1. When TAH or TAL sounds, monitor the temperature profile closely.
2. If deviation still persists, change controller to manual mode.
TAH: Decrease hot utility flowrate by adjusting CV-113 (CV-124, CV-153,
CV-158, CV-164).
TAL: Increase hot utility flowrate by adjusting CV-113 (CV-124, CV-153,
CV-158, CV-164).
3. If unresolved, emergency shut down of unit for further inspection.
Pressure Alarms
1. When PAH or PAL sounds, monitor pressure profile of column closely.
For total condenser (DC-101, DC-103 and DC-104)
PAH: Increase cold utility flowrate to condenser by adjusting CV-110
(CV-156, CV-161).
PAL: Decrease cold utility flowrate to condenser by adjusting CV-110
(CV-156, CV-161).
For partial condenser (ST-101 and DC-102):
PAH: Increase distillate flow by adjusting CV-122 (CV-151).
PAL: Decrease distillate flow by adjusting CV-122 (CV-151).
3. If unresolved, emergency shut down of unit for further inspection.
IX.3.4 Reactor (RX-101 and RX-102)
1. Set all controllers to manual mode and close bypass valve, MV-109 (MV111).
2. Ensure product outlet valve, CV-135 (CV-138) is closed.
3. Open CV-134(CV-137) to allow air in and CV-133(CV-136) to introduce
fuel. Make sure the mole ratio of air to fuel is 42:1.
4. Start the burner to allow combustion of fuel.
5. Once desired temperature (700 oC) is reached, open MV-110 (MV-119) to
introduce feed to reactor.
6. Adjust opening of product valve, CV-135 (CV-138) once desired pressure
(3.6 bar, 1.8 bar) is obtained.
7. Set all controllers to automatic mode when steady state is reached.
119 | P a g e

Normal Operation:
1. Monitor temperature and pressure of reactor constantly to ensure normal
operation.
2. Take sample of product every 8 hours and perform analysis to determine
the composition.
3. Ensure there is sufficient fuel source available.
1.
2.
3.
4.
5.
6.
7.
8.

Decrease feed flow gradually.
Decrease fuel flow to reactor by adjusting CV-133 (CV-136).
Decrease air flow proportionally by adjusting CV-134 (CV-137).
Stop feed flow and close CV-133 (CV-136) to stop fuel flow.
Close MV-110 (MV-119) to prevent backflow.
Fully open CV-135 (CV-138) to depressurize reactor.
Increase air flow to reactor by adjusting CV-134 (CV-137) to cool down
reactor.
9. Close CV-134 (CV-137) to stop air flow after reactor cools down.
Emergency Response:
Temperature Alarms
1. When TAH or TAL sounds, monitor temperature profile closely.
TAH: Decrease fuel flow to reactor by adjusting CV-133 (CV-136).
TAL: Increase fuel flow to reactor by adjusting CV-133 (CV-136).
3. If unresolved, emergency shut down of unit for inspection
maintenance.
Pressure Alarms
1. When PAH or PAL sounds, monitor pressure profile of reactor closely.
PAH: Increase opening of CV-135 (CV-138).
PAL: Decrease opening of CV-135 (CV-138).
3. If unresolved, emergency shut down of unit for inspection
maintenance.
and
and
IX.3.5 MEA Scrubber (SC-101)

2. Ensure outlet valves CV-120, CV-127 and drain valve, MV-107 are closed.
3. Activate pump PM-103 and open CV-118 to allow flow of fresh MEA
solvent to solvent tank (SU-101).
4. Once level in SU-101 is reached, open CV-117 to introduce solvent into
scrubber.
5. Once desired level (0.7m) of solvent in scrubber is reached, activate pump
PM-102 and open solvent outlet valve CV-120.
6. Readjust the opening of CV-117 to maintain desired level in scrubber.
7. Introduce feed to column and adjust CV-117 to ensure mole ratio of MEA
solvent to feed gas is 6.7 to 1.
120 | P a g e

8. Open CV-127 once desired pressure (3.8 bar) of column is reached.
9. Set controllers to automatic mode once steady state is reached.
Normal Operation:
1. Monitor pressure and level of scrubber constantly to ensure normal
operation.
2. Monitor flowrate of solvent and feed to scrubber to ensure mole ratio is
always 6.7 to 1 for efficient removal of CO2.
3. Monitor temperature of S-35 to avoid
the return of high temperature
recycled MEA to SU-101.
4. Take sample of gas outlet every 8 hours and perform analysis to
determine the composition.
5. Ensure sufficient fresh MEA solvent is available.
1.
2.
3.
4.
5.
6.
Set controllers to manual mode.

Decrease feed flow gradually and decrease MEA flow by adjusting CV-117.
When the feed flow stops, deactivate pump, PM-103 and close CV-118.
Close MEA solvent inlet valve by adjusting CV-117.
Deactivate pump, PM-102 and close solvent outlet valve, CV-120.
Open MV-107 to drain remaining solvent in scrubber and to depressurise
column.
Emergency Response:
Pressure Alarms
1. When PAH or PAL sounds, monitor pressure profile of scrubber closely.
PAH: Increase product gas flow by adjusting CV-127.
PAL: Decrease product gas flow by adjusting CV-127.
maintenance.
Level Alarms
1. When LAH or LAL sounds, monitor level of solvent storage tank (SU-101)
closely.
LAH: Decrease fresh MEA flow to SU-101 by adjusting CV-118.
LAL: Increase fresh MEA flow to SU-101 by adjusting CV-118.
Temperature Alarm
1. When TAH sounds, monitor temperature of S-35 closely.
TAH: Increase cooling water flow to HE-106 by adjusting CV-126.
IX.3.6 Pressure Swing Adsorption Unit (PSA)
1. Set controllers to manual mode.
2. Ensure all valves (BV-101 to BV-114 and SV-101 to SV-104) in PSA unit
are closed.
121 | P a g e

3. Open BV-101, BV-102 and BV-103 to pressurise PSA-101, PSA-102 and
PSA-103.
4. Close BV-103 once pressure of PSA-103 reaches 7 bar.
5. Close BV-102 once pressure of PSA-102 reaches 13.5 bar.
6. Open BV-105 once pressure of PSA-101 reaches 19.7 bar.
7. Open BV-112 to pressurise PSA-102.
8. Once, PSA-102 reaches 19.7 bar, open BV-102 and BV-106 to allow
adsorption to occur in PSA-102. At the same time, close BV-101 and BV105.
9. Open BV-109 to pressurise PSA-103 using depressurising stream from
PSA-101.
10. Switch the controller back to automatic mode to allow Programmable
Logic Controller (PLC) to control the sequence of PSA cycles.
Normal Operation:
1. Monitor the cycle time and sequence of cycle.
2. Monitor the pressure and temperature of each column.
3. Take sample of hydrogen every 8 hours and perform analysis to determine
the composition.
1. Switch controllers to manual mode.
2. When the feed flow stops, close all feed inlet valves (BV-101 to BV-104).
3. Close all other block valves (BV-105 to BV-114) and open all the switching
valves (SV-101 to SV-104).
4. Purge all the columns (PSA-101 to PSA-104) with nitrogen gas.
Emergency Response:
Temperature Alarm
1. When TAH sounds, monitor temperature profile of the columns closely.
Pressure Alarm
1. When PAH sounds, monitor pressure profile of the columns closely.
-If deviation persists, trip PSA unit using interlock valve, IV-103. [This is
because isolation of any column from the system will disrupt the sequence of
cycle and thus the efficiency of unit.]
IX.3.7 Crystalliser (CR-101)
1.
2.
3.
4.
5.
Set controller to manual mode.

Introduce coolant to crystalliser.
Turn on the motor to start the rotating blades.
Introduce feed to crystalliser.
To achieve desired temperature of product (35oC), adjust the coolant
outlet flowrate (CV-166).
6. Set the controllers to automatic mode once steady state is reached.
122 | P a g e

Normal Operation:
1. Monitor the temperature of the solid naphthalene and make sure it is
within normal operating condition. Adjust the coolant outlet flowrate if
necessary.
2. Take sample of naphthalene every 8 hours and perform analysis to
determine its composition.
1.
2.
3.
4.
5.
6.
7.
Set controller manual mode.

Decrease feed flow to crystalliser gradually.
Decrease coolant flow to crystalliser.
Stop feed flow to crystalliser.
Turn off motor to stop rotating blades.
Stop coolant flow to crystalliser.
Fully open CV-166 to allow coolant to flow out of crystalliser.
Emergency Response:
Temperature alarm
1. When TAH sounds, monitor the temperature profile of product stream
closely.
2. If deviation still persists, change controller to manual mode and decrease
the coolant outlet flowrate by adjusting CV-166.
maintenance.
IX.3.8 Furnace (F-101 and F-102)
1.
2.
3.
4.
5.
6.

Open CV-129 (CV-131) to allow air in.
Introduce fuel to furnace by opening CV-128 (CV-130).
Make sure the mole ratio of air to fuel is 10.5:1.
Start the burner.
Once the desired temperature (700 oC) is achieved, introduce feed into
furnace for heating.
7. Set the controllers to automatic mode when steady state is reached.
Normal Operation:
1. Monitor the temperature of heated stream constantly to ensure it is within
normal operating condition.
2. Ensure there is sufficient fuel source available.
1.
2.
3.
4.
5.
6.

Reduce feed flow to furnace gradually.
Decrease fuel flow by adjusting CV-128 (CV-130).
Decrease air flow by adjusting CV-129 (CV-131).
Stop feed flow and close CV-128 (CV-130) to stop fuel flow.
Increase air flow to furnace by adjusting CV-129 (CV-131) to cool down
furnace.
7. Close CV-129 (CV-131) to stop air flow after furnace cools down.
123 | P a g e

Emergency Response:
Temperature Alarms
1. When TAH or TAL sounds, monitor temperature profile of heated stream
closely.
TAL: Increase fuel (CV-128, CV-130) and air flowrate (CV-129, CV-131).
TAH: Decrease fuel (CV-128, CV-130) and air flowrate (CV-129, CV-131).
3. If unresolved, emergency shut down of unit.
XI.4 Control Philosophy and Strategy
XI.4.1 Control System for Distillation Column with Total Condenser
(DC-103)
Equipment Description: To separate benzene from toluene and naphthalene.
Control strategy: Parameters to be controlled in a distillation columns are
column pressure, temperature, level of kettle reboiler and reflux drum level.
Pressure and temperature are the main factors that will affect the separation in a
distillation column, thus precise controls are needed for these two parameters.
Column pressure is controlled by manipulating the flow of cooling water to
condenser whereas the flowrate of steam is used to control the temperature of
the column. Besides, reflux flow also needs to be controlled in order to ensure
desired product quality is achieved. For the control of reflux drum level, a
feedback system is applied and the distillate flow is manipulated. For a kettle
reboiler, the holdup of bottom liquid is within the reboiler itself (Smith, 2012),
hence the level of reboiler is controlled. A feedback control loop is used in
controlling the level of reboiler by manipulating bottom product flowrate.
Table XI.4.1:
condenser
Control
Control
Variable
Column
pressure
Disturbances
Temperature
of column
Reflux
flow(Flow
outlet
from
CV-155)
variables
for
distillation
column
with
total
Manipulated
variable
Cooling water
flowrate
Type
of
controller
PI
Control
Strategy
Feedback
Set
point
1.8 bar
-Cooling water
temperature
-Steam
temperature
-Feed
temperature
Steam flowrate
PID
Feedback
164.2 oC
-Flow inlet
CV-155
Flow inlet
CV-155
PI
Feedforward
102.9
kmol/h
-Feed
temperature
-Cooling water
temperature
-Steam
temperature
to
to
124 | P a g e

Kettle
reboiler liquid
level
-Steam
temperature
Bottom
product
flowrate
Feedback
0.02 m
Reflux
level
-Cooling water
temperature
-Steam
temperature
Distillate
flowrate
Feedback
0.5 m
drum
Remark: Same control strategy applied to DC-101 and DC-104.
Figure XI.4.1: Control system for distillation column with total condenser
XI.4.2 Control System for Distillation Column with Partial Condenser
(DC-102)
Equipment Description: To purify product by removing light hydrocarbon as
residual gas.
Control Strategy: Control system for distillation column with partial condenser
is similar to that of distillation column with total condenser, except for the control
of column pressure and level in reflux drum. Column pressure in distillation
column with partial condenser is controlled by manipulating the distillate flow. As
for the control of reflux drum level, flowrate of cooling water to condenser is
manipulated. Other parameters such as temperature of column, reflux flow,
reflux drum level and kettle reboiler level apply the same control strategies as in
distillation column with total condenser.
125 | P a g e
Table XI.4.2: Control variables for distillation column with partial

condenser
Control
Variable
Column
pressure
Disturbances
Manipulated
variable
Distillate
flowrate
Type
of
controller
PI
Control
Strategy
Feedback
Set
point
3.2 bar
Temperature
of column
-Cooling water
temperature
-Steam
temperature
-Feed
temperature
Steam
flowrate
PID
Feedback
137.7 oC
Reflux
flow(Flow
outlet
from
CV-150)
-Flow inlet to
CV-150
Flow inlet to
CV-150
PI
Feedforward
41.4
kmol/h
Kettle
reboiler liquid
level
-Steam
temperature
Bottom
product
flowrate
Feedback
0.03 m
Reflux
level
-Cooling water
temperature
-Steam
temperature
Cooling water
flowrate
Feedback
0.35 m
drum
-Feed
temperature
-Steam
temperature
-Cooling water
temperature
Remark: Same control strategy applied to ST-101.
Figure XI.4.2: Control system for distillation column with partial condenser
126 | P a g e

XI.4.3 Control System for Reactor (RX-101)
Equipment Description: To produce benzene through dehydroaromatization
reaction.
Control Strategy: Dehydroaromatization is an endothermic process, thus heat
needs to be supplied in order to maintain the reactor temperature at 700oC. Heat
is produced by the combustion of fuel inside the reactor. Hence, temperature of
reactor can be controlled by the flowrate of fuel to reactor. Besides, pressure of
the reactor can be maintained by controlling the product flow. The control
strategy used in both temperature and pressure control are feedback control. A
ratio controller is used to control the ratio of fuel to air to reactor by varying the
air flow. This is to ensure that there is sufficient oxygen for complete combustion
of fuel. Feed forward control is used to control the feed flow to reactor in order
to control residence time of reactant in the reactor.
Table XI.4.3: Control variables for reactor
Control
Variable
Temperature
of reactor
Disturbances
Pressure
reactor
of
-Feed
temperature
-Feed flowrate
Manipulated
variable
Flowrate
of
fuel
to
reactor
Type
of
controller
PID
Control
Strategy
Feedback
Set
point
700.0 oC
-Feed pressure
-Feed flowrate
Product
flowrate
PI
Feedback
3.0 bar
Feed flow to
reactor
(Outlet from
CV-132)
-Feed flow
CV-132(Inlet
CV-132)
to
to
Feed flow to
CV-132(Inlet
to CV-132)
PI
Feedforward
6465.0
kmol/h
Mole ratio of
fuel to air
-Composition
fuel
of
Air flow
reactor
PID
Ratio
1:42
to
Remark: Same control strategy applied to RX-102.
Figure XI.4.3: Control system for reactor
127 | P a g e

XI.4.4 Control System for Flash (FV-101)
Equipment Description: To separate vapour and liquid fraction of feed.
Control Strategy: Pressure of the flash vessel is controlled by the flow of
vapour in a feedback control loop. On the other hand, liquid outlet flow controls
the liquid level in flash. Flowrate of feed inlet is controlled with feed-forward
control to ensure efficient separation.
Table XI.4.4: Control variables for flash
Control
Variable
Pressure
of flash
Disturbances
Manipulated
variable
Vapour outlet
flow
Type
of
controller
PI
Control
Strategy
Feedback
Set point
Level
flash
in
-Feed flowrate
-Feed
temperature
Liquid
flow
Feedback
3.22 m
Feed flow
to
flash
(Outlet
flow from
CV-102)
-Inlet
feed
flow to CV102
Inlet feed flow

to CV-102
PI
Feedforward
996.30
kmol/h
-Feed
pressure
-Feed flowrate
outlet
60.4 bar
Remark: Same control strategy applied to FV-102.
Figure XI.4.4: Control system for flash

128 | P a g e

XI.4.5 Control System for Compressor(C-101)
Equipment Description: Compressor is used to increase the pressure of gas
stream.
Control Strategy: As high temperature will damage and spoil the compressor
internal parts, a temperature control is installed at the inlet of compressor. The
temperature control applies feedback control strategy and the flowrate of cooling
water to cooler is manipulated in order to maintain the desired inlet temperature.
When the feed flow to compressor is too low and insufficient for the speed of
compressor, the turbine blades will lose their forward thrust resulting in a
reverse movement in the shaft (Emerson Process Experts, 2010). This condition
is known as surge and it can have catastrophic effect on the compressor. To
prevent surge from happening, a feedforward control is used to control the feed
flow to compressor by manipulating the anti-surge flow from outlet. Moreover,
the speed of motor can be used to control the outlet pressure.
Table XI.4.5: Control variables for compressor
Control
Variable
Temperature
of compressor
inlet
Disturbances
Manipulated
variable
Flowrate
of
cooling water
to cooler
Type
of
controller
PID
Control
strategy
Feedback
Set
point
43.0 oC
Flow
to
compressor
-Feed flowrate
Flowrate
of
anti-surge line
PI
Feedforward
6972.8
kmol/h
Pressure
of
compressor
outlet
-Inlet pressure
-Feed flowrate
Motor speed
PI
Feedback
2.7 bar
-Temperature of
cooling water
-Cooling water
flowrate
-Feed flowrate
Remark: Same control strategy applied to C-102 and C-103.
Figure XI.4.5: Control system for compressor

129 | P a g e

XI.4.6 Control System for Dehydrator (DH-101 and DH-102)
Equipment Description: To remove water vapour from the feed stream using
silica gel as adsorbent.
Control Strategy: Only one dehydrator will be operating at a time, the other
dehydrator will be in regeneration or standby mode. Pressure of the dehydrator
is controlled by the flow of vapour outlet in a feedback control system.
Table XI.4.6: Control variable for dehydrator
Control
Variable
Pressure
of
dehydrator
Disturbances
-Feed flowrate
-Feed
pressure
Manipulated
variable
Flowrate
of
vapour outlet
Type
of
controller
PI
Control
strategy
Feedback
Set point
60.1 bar
Figure XI.4.6: Control system for dehydrator
130 | P a g e

XI.4.7 Control System for Furnace (F-101)
Equipment Description: To heat up streams to targeted temperature.
Control Strategy: Temperature control is the priority control in furnace where
the temperature of the heated outlet stream is being controlled. A feedback
control is used to control the temperature of heated outlet stream and the fuel
flowrate is manipulated in this control. A ratio controller is used to control the
ratio of fuel to air in order to ensure complete combustion of fuel in furnace. Air
flow (to furnace) is manipulated in this ratio control system.
Table XI.4.7: Control variables for furnace
Control
Variable
Temperature
of
heated
stream
Disturbances
Mole ratio of
fuel to air
-Fuel
Composition
-Feed flowrate
-Feed
temperature
Manipulated
variable
Flowrate
of
fuel
to
furnace
Type
of
controller
PID
Control
strategy
Feedback
Set point
Air flowrate
PID
Ratio
1:10.5
700.0 oC
Remark: Same control strategy applied to F-102.
Figure XI.4.7: Control system for furnace
131 | P a g e

XI.4.8 Control System for MEA Scrubber (SC-101)
Equipment Description: To remove CO2 from the feed stream using 30% MEA
solution as solvent.
Control Strategy: A ratio controller is used to control the mole ratio of MEA
inlet flow to that of feed flow to ensure efficient removal of CO2 from feed gas.
Pressure of the scrubber is controlled by varying the product gas outlet using
feedback control. Level in scrubber is controlled by varying the MEA solvent
outlet flow. The level in the MEA storage tank is maintained by manipulating the
make-up MEA flow.
Table XI.4.8: Control variables for MEA Scrubber
Control
Variable
Mole ratio of
MEA flow to
feed flow
Disturbance
Manipulated
variable
MEA flowrate
to scrubber
Type
of
controller
PID
Control
strategy
Ratio
Set
point
6.7:1
Pressure
scrubber
of
-Feed flowrate
-Feed pressure
Product
outlet
PI
Feedback
3.8 bar
Level
scrubber
in
-Inlet flow of
MEA solvent to
scrubber
-Feed flowrate
MEA
solvent
outlet flow
Feedback
0.7 m
Level of MEA
storage tank
-Flowrate
of
recycled MEA
Make-up MEA
flowrate
Feedback
1.62 m
-Feed flowrate
gas
Figure XI.4.8: Control system for MEA Scrubber
132 | P a g e

XI.4.9 Control System for Crystalliser (CR-101)
Equipment Description: To crystallise liquid naphthalene to solid naphthalene.
Control strategy: Cascade control is used to control the outlet temperature of
the naphthalene product. Primary measured variable is the temperature of solid
naphthalene while the second measured variable is the flow of coolant outlet.
Flow of coolant outlet is manipulated in this cascade control and cascade control
speeds up the response towards changes in the solid naphthalene temperature
by reducing the phase lag.
Table XI.4.9: Control variable for crystalliser
Control
Variable
Temperature
of
solid
naphthalene
Disturbances
-Temperature of
coolant
-Flowrate
of
coolant
Manipulated
variable
Outlet flow of
coolant
Type
of
controller
Master loop:
PID
Slave
PI
Control
strategy
Cascade
Set point
35oC
loop:
Figure XI.4.9: Control system for crystalliser
133 | P a g e

XI.4.10 Control System for Pressure Swing Adsorption Unit (PSA)
Equipment Description: To remove hydrogen from the recycled gas stream.
Table XI.4.10: Process description for eight-step PSA cycle
Step
1
Name
Adsorption
Explanation
-Feed gas enters to the adsorbent bed from the
bottom of column. Adsorbent removes the
strongly adsorbable component while the less
strongly adsorbed gas is withdrawn as product.
Pressure Equalisation
-Adsorption in step 1 continues. However, a

portion of the product is involved in step 8 to
repressurise another adsorbent bed to adsorption
pressure.
1st Depressurisation
-Adsorbent bed is depressurised to first

intermediate pressure by withdrawing gas from
product end. The withdrawn depressurisation gas
is used in 1st repressurisation (step 7).
2nd Depressurisation
-Additional depressurisation gas is withdrawn

from the product end of bed until its pressure
drops to second intermediate pressure. Gas
withdrawn is introduced to another bed which
undergoes purge step (step 6).
Dump
-Void space and desorbed gas is removed from

the bed through the waste-gas withdrawn.
Purge
-Purge gas from bed which undergoes step 4 (2nd

depressurisation) is introduced from the product
end and waste purge gas is withdrawn from the
bottom.
1st Repressurisation
-Adsorbent bed is repressurised to fourth

intermediate level which is about or slightly lower
than
the
first
intermediate
pressure.
Pressurisation gas is obtained from step 3 and is
introduced from the product end.
2nd Repressurisation
-Part of the product gas (from step 2) is sent to

the adsorbent bed via the product end to further
repressurise the bed. After this step, bed is ready
to start step 1 of the cycle.
134 | P a g e

A complete PSA cycle comprises of 8 sub-cycles and the sub-cycle details are as
follow:
*Note: All other valves which are not mentioned will be closed.
Sub-cycle 1:
Bed
PSA-101
PSA-102
PSA-103
PSA-104
Step
1
7
5
3
Actions
Open BV-101 and BV-105.
Open BV-110.
Open SV-103.
Open BV-110.
Step
2
8
6
4
Actions
Open BV-101, BV-105 and BV-112.
Open BV-112.
Open BV-114 and SV-103.
Open BV-114.
Step
3
1
7
5
Actions
Open BV-109.
Open BV-109.
Open SV-104.
Step
4
2
8
6
Actions
Open BV-111.
Open BV-113.
Step
5
3
1
7
Actions
Open SV-101.
Open BV-110.
Open BV-110.
Sub-cycle 2:
Bed
PSA-101
PSA-102
PSA-103
PSA-104
Sub-cycle 3:
Bed
PSA-101
PSA-102
PSA-103
PSA-104
Sub-cycle 4:
Bed
PSA-101
PSA-102
PSA-103
PSA-104
Sub-cycle 5:
Bed
PSA-101
PSA-102
PSA-103
PSA-104
135 | P a g e

Sub-cycle 6:
Bed
PSA-101
PSA-102
PSA-103
PSA-104
Step
6
4
2
8
Actions
Open BV-112.
Open BV-114.
Step
7
5
3
1
Actions
Open BV-109.
Open SV-102.
Open BV-109.
Step
8
6
4
1
Actions
Open BV-111.
Open BV-113.
Sub-cycle 7:
Bed
PSA-101
PSA-102
PSA-103
PSA-104
Sub-cycle 8:
Bed
PSA-101
PSA-102
PSA-103
PSA-104
Figure XI.4.10: Control system for PSA unit
136 | P a g e

XI.5 Piping and Instrumentation Diagram (P&ID)
137 | P a g e
138 | P a g e
Section X. Economic Evaluation

MODULE CODE
GROUP
GA SUPERVISOR
ACADEMIC SUPERVISOR
DATE OF SUBMISSION
H83DPX
4
Dr Hii Ching Lik
Prof Dominic Foo
Mr. Rafil
18th APRIL 2016
AUTHORS:
Arati Banu A/P Verasingham (013802)
Group members:
NAME
Soh Yi Shin Elaine
Kim Tae Yeon
STUDENT ID
013332
013461
Chan Joel Kai Chin
011032
Fidelia Prasetya
011494
PROGRAMME
MEng Chemical with

Selangor, Malaysia
I | Page

Executive Summary
This design project focuses on a petrochemical plant based in the Northwest of
China. Chemical plants are established to compose a profit. The profitability of a
chemical plant can be best determined by estimating the total investment
needed along with the cost of production. In this context, in order to properly
execute the profitability of the petrochemical plant cost estimation was diligently
conducted.
The petrochemical plant analyzed, produces benzene from shale gas and
operates 24 hours a day for 330 days in a year. Apart from benzene, the plant
also produces marketable grade by-products. Hence, subsequently increasing
the overall profitability. This section showcases the detailed economic analysis
conducted.
X.1 Fixed Capital Investment
The fixed capital investment includes the cost to design, construct and install
necessities in a plant. The type of capital cost estimate executed is a Class 4
with regards to the Association for the Advancement of Cost Estimating
International (AACE).
The categories of cost which are considered in fixed capital investment as shown
below.
Inside battery limit investment (ISBL)
Offsite investment (OSBL)
Cost of engineering, contingency and

location
Cost of sub-plant, land and

infrastructure
X.1.1 ISBL
The inside battery limit consists of direct and indirect field cost. The ISBL costing
is one of the most important project cost.
Direct Field Cost
Indirect Field Cost
1. Field fabrication and testing for

equipment.
2. Installation
supervision
and
labour.
3. Bulk items; painting, wiring,
valves and piping.
1. Constructions costs on
outside battery limit
infrastructure
2. Field services and expenses
The factorial method was selected as the cost estimating approach; refer to
Appendix VII.X.
Ce = a+bSn
(Equation X.1.1.1)
Where;
Ce = Equipment Cost
a, b = Cost Constants
S = Size Parameter
N = Exponent of the Equipment Type
139 | P a g e

The equipment purchase cost, Ce was calculated using Equation X.1.1.1; after
which the equipment capital cost, C (ISBL) was calculated using Equation
X.1.1.2. Please refer to Appendix VII.X; Detailed Calculations.
C = =
= 1 ,, fPft[(1+fp)fm+(fer+fel+fi+fc+fs+fl)]
(Equation X.1.1.2)
Table X.1.1.1 Factors for Estimation of Fixed Capital Cost (Coulson, Richardson
and Sinnott, 2007).
Item
Process type -Fluids
Equipment Erection, fer
0.30
Piping, fp
0.80
Instrumentation and Control, fi
0.30
Electrical, fel
0.20
Civil, fc
0.30
Structures and Buildings, fs
0.20
Lagging and Paint, fl
0.10
Pressure
FP
0.01
2.00
0.10
1.30
0.5-7
1.00
50.00
1.50
Temperature
Ft
0-100
1.00
300.00
1.60
500.00
2.10
Equipment Material
Fm
Carbon steel
1.00
Aluminium and Bronze
1.07
Cast steel
1.10
304 stainless steel
1.30
Prior to calculating the cost of each equipment, a preliminary equipment design
sizing complete with safety margins was conducted; refer to Appendix VII.X for
the equipment sizing method. It was found that only one flash drum (FV-101),
the TSA Unit and the reactors required the use of stainless steel 304 (SS-304)
whereas all the other equipment were constructed from carbon steel (CS). The
operating conditions were also factored into the cost of the individual equipment
with reference to the process flow diagram conditions. Table X.1.2 shows the
summary of the ISBL costing in USD. All equipment was quoted as free on board
(f.o.b). The costing methodology can be found in Appendix VII.X.
140 | P a g e

Table X.1.1.2: Purchased Equipment Costings and Equipment Capital Cost.
Item No.
Heat Exchangers
Coolers
Heaters
Condensers
Reboilers
Crystaliser
Furnace
Reactors
Distillation Columns
Flash Drums
PSA Unit
TSA Unit
Membrane
Reflux Drum
Scrubber
Stripper
Trays
Packing
Storage Tanks
Turbine
Compressors
Pumps
Quantity
4
8
5
5
5
1
2
2
4
2
1
1
1
5
1
1
3
3
8
1
3
8
Material
CS
CS
CS
CS
CS
CS
CS
SS-304
CS
SS-304, CS
CS
SS-304
CS
CS
CS
CS
CS
CS
CS
CS
CS
CS
Total
Ce, USD
509,508.86
438,131.35
125,797.74
120,000.00
120,000.00
120,000.00
554,904.16
1,658,807.31
95,713.47
30,880.52
15,820.40
14,783.90
12,402.26
51,325.34
12,068.01
12,068.01
1,306.03
6,132.00
472,838.96
1,594,103.12
7,583,789.28
55,587.15
(ISBL), USD =
C, USD
3,787,265.97
1,497,633.34
444,982.96
384,000.00
384,000.01
384,000.01
3,728,955.94
13,028,272.58
306,283.11
106,812.17
50,625.28
55,291.80
39,687.23
164,241.09
38,617.63
38,617.63
80,882.97
43,622.40
1,513,084.68
7,651,694.96
24,268,125.70
161,202.75
57,800,780.20
The ISBL value was updated using the following equation;

2015
Cost in 2015 = 2007 2007

ISBL Cost in 2015, USD =
562.9
524.4
(Equation X.1.1.3)
57,800,780.20
= 61,926,264.13
X.1.2 OSBL
The outside battery limit cost (off-site cost) includes expenses that must be
made in order to build a new plant. This includes; power generation plants,
boiler plants, chiller plants and waste water treatment plants (hereinafter
referred to as the sub-plants). Apart from that, the OSBL also covers the
pipelines, laboratories, emergency services and site security. Typically OSBL is
estimated to be between 20-50% of the ISBL. In this study, the sub-plants were
costed individually in order to obtain a more accurate fixed capital cost. Hence it
was assumed that the remaining OSBL costs excluding the sub-plants would be
15% of the ISBL.
141 | P a g e

Table X.1.2.1: Sub-plant Cost.
Sub-Plant
Chiller Plant
Flare system
Boiler Plant
Waste Water Treatment Plant

(designed in Section VII.5)
Total Cost, USD

100,000.00
105,000.00 (John Zink Company LLC)
*Expander
= 985,074.20
*Boiler
= 133,144.
Deaerator
= 20,150.00
= 1,138,368.20
*Bioreactors, BR-101 and
BR-102
= 210,600.00
*Storage tank, ST-101
= 12,016.62
Clarifier, CL-101
(Aquatec-Maxicon)
= 130,000.00
Ultrafiltration Membrane, MR-102

(General Electric, GE)
= 113,951.00
Total Sub-Plant Cost, USD =
= 466,567.62
52,424,615.57
The equipment marked with an asterisk was done using the factorial method;
Equations X.1.1 and X.1.2 while the prices of the remaining equipment were
quotes from suppliers.
Total OSBL, USD = 0.15(61,926,264.13) + 52,424,615.57
= 61,713,555.19
X.1.3 Cost of Land and Infrastructure.

A typical benzene petrochemical plant inclusive of sub-plants and pipe networks
is approximately 70 acres; 283,280 m2. 35% of the land acquired will be used
for buildings (Durgachem, 2016).
Table X.1.3.1: Purchased Land and Infrastructure.

Expense
Size
Cost, USD
Total Cost, USD
Land
70 acres
141 per m2
39,942,480.00
(Buildingsguide, 2016)
Infrastructure
24.5 acres
10 per ft2 (China.cn, 2016)
Total Land + Infrastructure Cost, USD =
10,672,199.75
50,614,679.75
142 | P a g e

X.1.4 Cost of engineering, contingency and location
Table X.1.4.1: Engineering, Contingency and Location Factors (Coulson,

Richardson and Sinnott, 2007).
Item
Engineering Cost
Contingency
Location
Factor on ISBL + OSBL

0.10 (large plant)
0.10
0.61(China; indigenous)
ISBL + OSBL, USD = 123,639,819.32

Total Cost of Engineering, Contingency and Location, USD
= 0.10(123,639,819.32) + 0.1(123,639,819.32) + 0.61(123,639,819.32)
= 100,148,253.65
X.1.5 Total Fixed Capital Investment
The total fixed capital investment is the sum of the ISBL, OSBL, land, industrial
building, engineering, contingency and location.
Total Fixed Capital Investment, USD = 123,639,819.32 + 100,148,253.65
+ 50,614,679.75
= 274,402,752.71
X.2 Working Capital
The working capital is the amount of money required to start up the plant until it
starts to earn an income. This includes raw material and product inventories.
The working capital in this case was set to be 10% of the ISBL + OSBL.
Working Capital, USD = 0.1(123,639,819.32)
= 12,363,981.93
X.3 Variable Cost
Variable cost contributes to the petrochemical plants operating cost. This
includes the raw material (shale gas), utilities, consumables and effluent
disposal costs.
X.3.1 Raw Material
The cost of the shale gas supplied was assumed to be similar to natural gas. This
is mainly to do the inability to estimate the cost of shale gas as currently it is not
being sold in the market.
143 | P a g e

Table X.3.1.1: Annual Raw Material Cost.
Raw Material
Shale Gas
Total Used, kg/yr

165,290,400.00
Cost, USD
0.14 per kg
(O&G 360, 2015)
Total Cost, USD/yr

22,727,430
X.3.2 Utilities
The water required is 454,761,216.00 kg/yr (recycled every 2 weeks) and the
make-up water required is 1,239,131,520.00 kg/yr (Refer to Section III.8.5
Energy and Water Availability for the cost of water and electricity in China).
Table X.3.2.1: Annually Purchased Utilities Cost.
Utility
Water
Electricity
Natural Gas
Ammonia
Hot Oil
Total Required
1,693,892,736.00 kg/yr
210,365,433.43 kWh/yr
5,132,160.00 kg/yr
Cost, USD
Total Cost, USD/yr
0.0004 per kg
694,496.02
0.14 per kWh
30,022,092.47
0.14 per kg
705,672.00
0.16 per kg
(Agility
1,113,960.00
178,233.60
Refrigeration,
2016)
3.83 per kg
822,528.00 kg/yr
(Massenergy,
3,149,870.98
2016)
Total Utilities, USD/yr =
34,750,365.06
X.3.2.1 Utility Cost Saving Before and After Heat Integration.

Based on Table X.3.2.1.1 it was found that a cost saving of 61% was made from
the water utilities used (cooling water, chilled water and steam; to be generated
in the sub-plants). Whereas, a cost saving of 81% was made through the
reduction of natural gas as the
Table X.3.2.1.1: Purchased Utilities Cost Every Alternate Year.
Before Heat Integration
After Heat Integration
Flow Rate,
Total Cost,
Flow Rate, kg/
Total Cost,
kg/yr
USD per year
yr
USD per year
Water
1,165,207,680.00
477,735.15
454,761,216.00
186,452.10
Natural Gas
36,780,480.00
5,057,316.00
5,132,160.00
705,672.00
144 | P a g e

X.3.3 Consumables
The consumables mentioned are to be changed once a year.
Table X.3.3.1: Annually Purchased Consumables.
Total Required
Cost, USD
Total Cost, USD/yr
2000 per tonne
10 tonnes
20,000.00
(Guidechem, 2016)
35.00 per tonne
Zeolite
5 tonnes
(Zeoliteproducts,
175.00
2016)
Activated
1,960 per tonne
5 tonnes
9,800
Carbon
(ChemPub, 2016)
500.00 per tonne
Alumina
5 tonnes
(Saiadsorbents,
2,500
2016)
96,000 per tonne
Silica Gel
1 tonne
96,000
(Osha.gov, 2016)
38,410 per tonne
MO/HZSM-5
3 tonnes
(Katalco Import,
115,230.00
2016)
25,310 per tonne
MO2C/ZSM-5
3 tonnes
(Katalco Import,
75,930.00
2016)
800 per tonne
MEA
185.75 tonnes
148,598.51
(ICIS, 2016)
Total Consumables, USD/yr =
468,233.51
X.3.4 Effluent Discharge
Consumables
PTMSP
(membrane)
No charges were implied for effluent discharges as the discharges were in

accordance with the Ambient Air Quality Standards (GB3095-2012) and
Environmental Quality Surface Standards (GB3838-2012); refer to Section VII.
X.4 Fixed Cost of Production
An initial estimate for the fixed cost of production was carried out by assuming
4.8 operators per shift for 4 shifts with a salary of USD 60,000.00 per shift
position per year.
Table X.4.1: Fixed Production Cost.
Fixed Production Cost
Total Required
Operating Labour Cost, USD
864,000.00
Supervision, USD
216,000.00
(25% of operating labour)
Direct Salary Overhead, USD
432,000.00
(40% of operating labour)
Maintenance, USD
1,857,787.92
(3% OF ISBL)
Property Taxes and Insurance, USD
1,236,398.19
(1% of ISBL)
Total Fixed Production Cost, USD/yr =
4,606,186.12
145 | P a g e

X.5 Revenue
The project earns an income through sales of the main product; benzene and the
by-products; toluene, naphthalene, hydrogen, propane and carbon dioxide. Refer
to Appendix AI.4 Economic Potential Evaluation for the cost of the products.
Table X.5.1: Total Revenue.
Product
Benzene
Toluene
Napthalene
Hydrogen
Propane
Carbon Dioxide
Total Produced, MT/yr

64,611.76
4,645.40
7,877.94
12,975.81
16,371.75
183.90
Total Revenue, USD/yr =
Total Revenue, USD/yr

95,173,116.59
5,581,908.79
4,485,701.77
19,463,716.80
3,264,526.71
2,758.54
127,971,729.20
X.5.1 Increase in Revenue after the Environmental Analysis

Based on the environmental protection analysis, it was found that the carbon
dioxide gas leaving the stripper has adverse effects on the environment. Seeing
as the purity of the carbon dioxide was more than 93%, instead of contributing
to the carbon emission, the carbon dioxide was deemed fit to be sold. This
increased the total sales slightly; apart from avoiding the carbon emission tax.
X.6 Tax and Depreciation
The standard corporate income tax in China is 25%, but the tax rate can be
reduced to 15% for qualified enterprises which are engaged in industries
encouraged by the China government for new high-technology enterprises
(HNTE) along with a 50% super deduction for qualifying R&D expenditure
(Deloitte, 2016). The selected membrane and catalyst will be developed
throughout the plant life; only a fraction of actual R&D cost. Hence, a tax
allowance of USD 150,580.00 per year can be deducted from the gross profit to
obtain the taxable income (Deloitte, 2016).
The approved depreciation of fixed assets by the State Administration of
Taxation in China is calculated using the straight line method. The depreciation
of the purchased equipment was calculated using the total cost of the equipment
over the useful equipment life; 20 years. The depreciation of the purchased
equipment was USD 674,718.39. However, seeing as realistically the entire pla
nt would decrease in value the depreciation of the plant was estimated to be
8% of the total fixed capital.
X.7 Profit and ROI
The profit and return of investment (ROI) are the principals that determine if the
project is worth investing in. In order to convince the management, the
proposed project; benzene plant should make a sound investment. With
reference to Section X.2, X.5.1 and X.1.5;
Working Capital, USD
= 12,363,981.93
146 | P a g e

Sales Revenue, USD per year
= 127,971,729.20
Total Fixed Capital Cost, USD
= 274,402,752.71
Table X.7.1: Profit and ROI Summary.

Evaluation
Total operating cost, USD
=
Profit before Depreciation Interest and Tax, USD
=
Depreciation, USD
=
Profit before Interest and Tax, USD
=
Interest Rate (4% per year)
=
Profit before Tax, USD
=
Corporate Tax,USD
=
Final Profit After Tax, USD
=
Pre-tax ROI (%)
=
ROI (%)
=
*Refer to Appendix VII.X for the formulas used in Table VII.X.7.1
Annual Cost
62,532,214.69
65,439,514.51
21,952,220.22
64,764,796.11
2,617,580.58
62,147,215.53
8,385,058.74
53,762,156.79
22
19
In the first year, the pre-tax ROI is 22% and the after tax ROI is 19%. The
typical ROI for petrochemical industries is 20% (Coulson, Richardson and Sinnott,
2009). The difference between the pre-tax and after tax ROI showcases the
effects of taxation, interest and depreciation on the return of investment in the
industry.
X.8 Cash Flow Analysis
Figure X.8.1: Benzene Plant Cash Flow Diagram.

Figure X.8.1 is the projected cash-flow for the estimated life span of a chemical
plant; 30 years. The investment is spread out throughout the first 3 years of the
project; Table X.8.1. It was found that, tax payment commences from the 6th
year onwards. This is because since tax is implied based on the income; taxation
commences just as the income is generated. Table X.8.1 shows the typical startup schedule used to carry out the cash flow analysis. Please refer to Appendix
147 | P a g e

VIII.X, Table VII.X.3 for the tabulation of the cash flow analysis.
Table X.8.1: Typical Start-up Schedule.
Year
1 year
2nd year
Costs
30% of fixed capital
40% of fixed capital
30% of fixed capital + working capital + FCOP
+ 30% VCOP
st
3rd year
4th
FCOP + 90% VCOP
5th onwards
FCOP + VCOP
Revenues
0
0
30% of reve
nue
50% of reve
nue
90% of reve
nue
Point A to B showcases the investment required to design the plant. This

includes the start-up expenses as well as the working capital until an income is
earned.
Point B to C is when the cash flow starts decline at a slower rate. Point C marks
the turning point for the cash flow diagram. This is where the plant has started
generating an income from the sales of the products and by-products. The
shaded area ABCD represents the dept of the plant. Point D indicates the breakeven point. The break-even point is the point at which the revenue generated is
equal to the production cost; pay-back period. The pay-back period for the
studied benzene plant is 5.5 years.
The region from point D to E is positive. This means the plant has started to
obtain a return on the investment. Hence, it is from this point on that the plant
can start repaying the investors or the bank loans. Once a plant reaches the end
of the project life, the cash flow rate will decrease.
X.9 Net Present Value
The net present value is the sum of the present values of the future cash flows;
= =
=1 (1+)
(Equation X.9.1)
where;
CFn = cash flow in years,n
t = project life years i =interest rate
Net present values are more useful economic measurements compared to the
ROI as it considers the after-tax income; refer to Appendix VII.X, Table VII.X.3
for the NPV table. The NPV is equal to a USD of 476,200.31 (positive) so it is
worth investing.
X.10 Simple Pay-Back Time

=
Simple pay-back time =
286,766,734.64
55,729,167.33
(Equation X.10.1)
= 4.9 years
148 | P a g e

It was found that the simple pay-back time is 13% less than the actual payback
period including depreciation, interest and tax.
X.11 Discounted Cash Flow Rate of Return
Figure X.10.1: Discounted Cash Flow Rate of Return.

Figure X.10.1 illustrates the discounted cash flow rate of return (DCFROR) for
the benzene plant. DCFROR is a measuring tool for the efficiency of the capital
usage. It does not however show the profitability of the plant. The higher the
discounted cash flow, the better the project. This is a measure of the maximum
interest rate that the project can pay while still breaking even by the end of the
project life. DCFROR is even more useful than NPV as NPV changes based on the
plant capacity however DCFROR is independent of the plant capacity.
=
=1
(1+ )
=0
(Equation X.11.1)
where;
CFn = cash flow in years,n
t = project life years i =DCFROR
The value of i was calculated by equating Equation X.9.1 to 0. It was found that
the DCFROR is 30.5% which is much higher than the market interest rate of 4%.
Concluding, that the project is profitable and merit of being invested on.
149 | P a g e

X.12 Rate of Return
=
30
30
ROR =
1,400,998,341.28
30 3,709,194.58
(Equation X.12.1)
x 100% = 12.9%
X.12 Economic Evaluation Summary

Table X.12.1: Economic Evaluation Summary of Results
Economic Analysis
Plant Lifespan (years)
Pre-Tax Return of Investment, ROI (%)
Return of Investment, ROI (%)
Rate of Return, ROR (%)
Net Present Value (NPV)
Simple pay-back period
Payback Period (years)
Discounted Cash Flow Rate of Return, DCFROR (%)
Results
30
21
19
12.9
USD 476,200.31
4.9
5.5
30.5
In conclusion, it is concluded that the project is indeed profitable as it has a ROI

of 19% with an actual payback period of 5.5 years.
150 | P a g e
Appendix
Production of Benzene from Shale Gas through
Integrated Non-Oxidative Dehydroaromatization.
MODULE CODE
GROUP
ACADEMIC SUPERVISOR
DATE OF SUBMISSION
AUTHORS
NAME
H83DPX
4
Prof Dominic Foo
Mr. Rafil
18th April 2016
STUDENT ID
013802
Chan Joel Kai Chin
011032
Fidelia Prasetya
Kim Tae Yeon
Soh Yi Shin Elaine
011494
013461
013332
PROGRAMME
MEng Chemical with

Selangor, Malaysia
E | Appendix
AI. Appendix ............................................................................................. I

AI.1 Notation .......................................................................................... 1
AI.2 Design Basis Production Specifications. ............................................... 2
AI.3 Section III: Process Background Supporting Details .............................. 4
III.5.3 Process 3: Converting Methane to Aromatics Through Syngas and
Methanol ...................................................................................... 4
III.5.4 Process 4: Oxidative Coupling of Methane (OCM) ...................... 6
III.5.5 Process 5: Integrated Process ................................................ 9
AI.4 Equipment Selection ....................................................................... 10
AI.5 Catalyst Selection ........................................................................... 12
AI.6 Safety Evaluation ........................................................................... 13
AI.7 Economic Potential Evaluation .......................................................... 14
Process 1 Reaction Path ................................................................. 15
AI.8 Detail Calculation ........................................................................... 18
Conversion of Feed........................................................................ 18
Flash 1 (FV-101) ........................................................................... 19
Flash 2 (FV-102) ........................................................................... 20
Reactors ...................................................................................... 20
Recycle Loop ................................................................................ 22
Overall Mass Balance ..................................................................... 23
Example Calculation For Comparison Between Manual Mass Balance and
HYSYS Simulation ......................................................................... 24
Calculation of HE-101 .................................................................... 24
Calculation for C-101 ..................................................................... 30
Calculation of PM-101 ................................................................... 33
Calculation of CR-101 .................................................................... 34
Calculation of RX-102 .................................................................... 35
AI.8 Reference ...................................................................................... 37
AII. Record Cards..................................................................................... 49
F | Appendix
AIII Appendix for Technical Data Used for Design......................................... 51

AIII.VI.1 ENERGY RECOVERY AND UTILITY CALCULATION .......................... 51
AIII.VII.1 ENVIRONMENTAL PROTECTION ................................................ 55
VII.3.2.2 Leopold Matrix Table ........................................................ 55
VII.4.3.1 Calculations .................................................................... 56
VII.6.1 Local Ambient Air Quality Standards ..................................... 59
VII.6.2 Environmental Quality for Surface Water Standards ................ 60
AIII.X.1 ECONOMIC EVALUATION ............................................................ 61
AIV Appendix for Detailed Design Calculation .............................................. 70
AIV. VI.I: Formula and Graph for DC ....................................................... 70
AIV. VI.1: DC-101 Calculation ................................................................. 78
AIV. VI.2: SC-101 Calculation ................................................................. 87
AIV. VI.3: RX-101 Calculations ............................................................... 95
VI.3.4.3.1: Alpha and Beta Calculation ............................................ 95
VI.3.4.3.2: MATLAB Simulation Algorithm ........................................ 96
VI.3.4.3.3: Space Time, Ratio of L/D Calculation & Pressure Drop Calcula
tion ............................................................................................. 97
VI.3.4.3.4: Conversion, Selectivity and Yield Percentage of Methane and
Expected Products ........................................................................ 98
VI.3.4.2.5: Products, Pressure Drop, Methane Conversion & Temperature
Profile Graphs ........................................................................... 100
AIV. VI. 4: DC-102 Calculation .............................................................. 104
AIV. VI. 5: DC-103 Calculation .............................................................. 113
AV. Detailed HAZOP Study ...................................................................... 122
HAZOP 122
FV-101 ...................................................................................... 122
Part considered: FV-101 .............................................................. 122
DH-101 & DH-102 ....................................................................... 125
Part considered: DH-101 and DH-102 ............................................ 125
MR-101 & TB-101 ....................................................................... 129
Part considered: MR-101 and TB-101 ............................................ 129
DC-101 ...................................................................................... 132
Part considered: DC-101 .............................................................. 132
SC-101 ...................................................................................... 142
G | Appendix
Part considered: SC-101 .............................................................. 142

SU-101 ...................................................................................... 147
Part considered: SU-101 .............................................................. 147
Part considered: ST-101 .............................................................. 150
F-101 & F-102 ............................................................................ 154
Part considered: F-101 and F-102 ................................................. 154
RX-101 & RX-102 ........................................................................ 156
Part considered: RX-101 and RX-102 ............................................. 156
Part considered: C-101, 102, 103 ................................................. 164
FV-102 ...................................................................................... 168
Part considered: FV-102 .............................................................. 168
PSA-101 .................................................................................... 172
Part considered: PSA-101 ............................................................ 172
CR-101 ...................................................................................... 173
Part considered: CR-101 .............................................................. 173
DC-102 ...................................................................................... 176
DC-103 ...................................................................................... 185
DC-104 ...................................................................................... 196
H | Appendix
AI. Appendix
MODULE CODE
GROUP
ACADEMIC SUPERVISOR
DATE OF SUBMISSION
AUTHORS
NAME
Soh Yi Shin Elaine
Kim Tae Yeon
H83DPX
4
Prof Dominic Foo
Mr. Rafil
18th April 2016
STUDENT ID
013332
013802
013461
Chan Joel Kai Chin
011032
Fidelia Prasetya
011494
PROGRAMME
MEng Chemical with

Selangor, Malaysia
I | Appendix
AI.1 Notation
Table A1.1: Useful Notations.
Notation
T
P
E
MF
mF
Co
D
B
LK
HK
HNK
Nm
Rm
R
Eq
Hf
CO2
N2
CH4
CH3OH
C2H2
C2H6
C3H8
C4H10
C5H12
H2O
C6H6
C10H8
C7H8
C8H10
H2
C2H4
C3H6
C
O2
Meaning
Temperature
Pressure
Energy
Mass Flowrate
Molar Flowrate
Conversion
Distillate
Bottom Product
Light Key
Heavy Key
Heavy Non Key
Minimum Number of Stage
Minimum Reflux Ratio
Reflux Ratio
Equation
Heat of formation
Carbon Dioxide
Nitrogen
Methane
Methanol
Acetylene
Ethane
Propane
Butane
Pentane
Water
Benzene
Naphthalene
Toluene
Xylene
Hydrogen
Ethylene
Propylene
Carbon (Coke)
Oxygen
1 | Appendix
AI.2 Design Basis Production Specifications.

Table AI.2.1: Production Capacity of Propane.
Product
Propane
Chemical Structure
Chemical Formula
Production Rate
Grade
IUPAC ID
Phase
Propane
Specifications
CAS Number
74-98-6
106-97-8
C3H8
14,716.40 tonne/year
1.68 tonne/hour
HD-5 93.51 wt%
Propane
Gas
Percentage
(wt%)
93.51
6.49
Chemical
Name
Propane
Butane
Table AI.2.2: Production Capacity of Hydrogen.

Product
Hydrogen
Chemical Structure
Chemical Formula
Production Rate
Grade
IUPAC ID
Phase
Benzene
Specifications
H2
47,256 tonne/year
5.50 tonne/hour
Industrial Grade 99.86 wt%
Hydrogen
Gas
CAS Number
Percentage
Chemical
(wt%)
Name
1333-74-0
99.86
Hydrogen
7727-37-9
0.14
Nitrogen
2 | Appendix
Table AI.2.3: Production Capacity of Naphthalene.

Product
Naphthalene
Chemical Structure
Chemical Formula
Production Rate
Grade
IUPAC ID
Phase
Naphthalene
Specifications
C10H8
12,264.00 tonne/year
1.40 tonne/hour
Industrial Grade 99.99 wt%
Napthalene
Crystal Pellets
CAS Number
Percentage
Chemical
(wt%)
Name
108-88-3
99.99%
Naphthalene
71-43.2
0.01
Toluene
Table AI.2.4: Production Capacity of Toluene.

Product
Toluene
Chemical Structure
Chemical Formula
Production Rate
Grade
IUPAC ID
Phase
Benzene
Specifications
C7H8
3504.00 tonne/year
0.4 tonne/hour
Commercial Grade 90.87 wt%
Toluene
Liquid
CAS Number
Percentage
Chemical
(wt%)
Name
108-88-3
90.87
Toluene
5.56
Benzene
3.57
Naphthalene
3 | Appendix
AI.3 Section III: Process Background Supporting Details

III.5.3 Process 3: Converting Methane to Aromatics Through Syngas
and Methanol
Conversion Method
Type of Reaction
Mode
Catalyst
Status
:
:
:
:
:
:
5
Non-direct
Exothermic
Continuous
ZN-Modified-Nano HZSM-5
Patented
Brief Overview
There are several methods to produce aromatics from natural gas. One of which
involve converting methanol as an intermediate. Methanol can be considered as
an economical feedstock for hydrocarbon. Using two steps, methanol can be
produced from natural gas.
Recently, Zn-Modified-Nano HZSM 5 was found to be the best catalyst to convert
methanol to aromatics. This catalyst results in a high conversion and high yield
to produce BTX (Benzene, Toluene, and Xylene). Although the conversion is high,
the stability of the catalyst is poor.
Process Description
Figure III.5.3.1 Block Diagram on Process 3.

First, methane is converted to syngas through steam reforming or partial
oxidation. Then, the syngas produced will be converted to methanol using Cu,
ZnO or Al2O3 as the catalyst.
Methanol To Aromatics
Figure III.5.3.2 Methanol Conversion to Aromatics.

The two main steps to convert methanol to hydrocarbons are;
1. Methanol to Olefins (MTO) Process
2. Olefins to Hydrocarbon
4 | Appendix
Temperature and pressure will affect the conversion of methanol to aromatics.

The highest selectivity is achieved at low pressure and high temperature.
(Gunawardena and Fernando).
Selectivity and Yields
Catalyst
0.5 wt%
Zn/NZ
Co. of
Methane
(wt%)
100
Yield
(%)
Selectivity (%)
C1C2
C3
C4
1.5
7.2
22.2
C5+
5.
3
B
2.5
C9+
C10H8
19.5
29.7
12.
1
2.1
Notes:
a) Yield wt%=conversion of methanol x selectivity x 100%
b) This process occurs in Fixed Bed Reactor with 1 bar and 400C as the
operating conditions.
Chemical Reaction:
1. Methane to Syngas
CH4 + H2O CO + 3H2
2. Syngas to Methanol
CO + 2H2 CH3OH
3. Dehydration of Methanol
2CH3OH CH3OCH3 + H2O
4. Dehydration of Dimethylether
CH3OCH3 C2H4 + H2O
5. Dehydrogenation of Olefins to Benzene, Toluene and Xylene

3C2H4 C6H6 + 3H2
4C2H4 C7H8 + 2H2 + CH4
4C2H4 C8H10 + 3H2
Overall Reactor Balance Equation:

21CH3OH C6H6 + C7H8 + C8H10 + 9H2 + 21H2O
Safety and Environmental Impacts

The overall process considered safe. The operating conditions necessary for the
reaction to occur are moderate. Thus it does not impose any significant risk.
benzene and toluene is noted as flammable at high temperatures, hazardous and
stable (Code 2-2-0). Ethylbenzene is noted as a chemical that will ignite under
elevated conditions and may cause serious residual injuries (Code2-3-0).
Dimethyl ether will ignite only if preheated, highly lethal and unstable at
elevated conditions.
5 | Appendix
This process produces carbon monoxide, a greenhouse gas which can contribute
to global warming. All of the waste from this process will be treated to a level
where it is accepted by Environmental Protection Agency (EPA) before it can be
released to the environment thus it will not impose a severe impact to the
environment.
Process 3 Overview
Pros
Cons
Exothermic Reaction
More than 2 Steps Conversion
Occurs at Moderate
Temperature
High Capital Cost

Selectivity and yields
toward benzene is low
III.5.4 Process 4: Oxidative Coupling of Methane (OCM)

Conversion Method
Type of Reaction
Mode
Catalyst
Status
:
:
:
:
:
:
3
Indirect
Exothermic and Endothermic
Continuous
Li2CO3/ZnO and Mo2/HZSM-5
Semi-Patented /Pateneted
Brief Overview:
One of the methods to produce the valuable heavy hydrocarbons from methane
is thorough the production of ethylene. Oxidative coupling of methane (OCM) is
a promising route to produce ethylene. In OCM, methane and oxygen are
reacted over a catalyst. This exothermic process produces ethylene and water.
Ethylene then undergoes hydrogenation. The product, ethane, is then dehydroaromatized to produce benzene. NaOH/CaO is the most common metal oxide
catalysts used in OCM. It operates at 740 and its methane conversion is 36%.
The catalyst has a selectivity towards C2+ is 67% and the yield of ethylene is
14.8%. It is inefficient due to the high temperature requirements. Also, the
volatility of catalyst at the reaction condition may cause reduction in mass of the
catalyst.
Process description

6 | Appendix
Pre-Treatment
The shale gas is treated to remove the alkanes from propane to pentane, carbon
dioxide and water. It is necessary to improve the overall efficiency of the process.
Reactor 1
It is the reactor where the OMC takes place. It operates at 740 with NaOH/CaO
catalyst to convert methane to ethylene which will be further converted to
ethane.
Selectivity and Yields:
Table III.5.4.1 Selectivity and Yield of Reactor 1 for Process 4.
Catalyst
Co of Methan(%)
Li2CO3/ZnO
Selectivity (%)
Yields (%)
C2H4
C2H4
67
14.8
36
Reactor 2
This is the hydrogenation reactor where ethylene is reacted with hydrogen over
nickel catalyst at 150 to from ethane. This is necessary because conversion of
ethylene to benzene is not feasible.
Reactor 3
Ethane is converted to benzene and toluene over a MO2C/ZSM-5 catalyst at
700oC. The unreacted methane from OCM reactor will also be converted to
benzene using the same catalyst. Hydrogen is also produced in the reaction and
it can be utilized in the hydrogenation reactor.
Table III.5.4.2 Selectivity and Yield of Reactor 2 for Process 4.
Catalyst
Reactant
Co
Mo2/ZSM-5
Methane
Ethane
0.0095
0.672
C2H6
0.1
0
C6H6
0.85
0.3
Selectivity
C2H4
C
0.05
0
0
0.02
C7H8
0
0.1
CH4
0
0.58
Chemical Reactions:
1. Reactor 1 (OCM)
2CH4 + O2 C2H4 +2H2O
2. Reactor 2 (Hydrogenation)
C2H4 + H2 C2H6
3. Reactor 3 (Dehydro-aromatization)
3 C2H6 C6H6 + 6H2
C2H6 + H2 2 CH4
7 C2H6 2 C7H8 + 13 H2
C2H6 2C + 3 H2
6 CH4 C6H6 + 9H2
7 | Appendix
2 CH4 C2H6 + H2
2 CH4 C2H4 + 2 H2
Overall Balanced Equation

10C2H6 + 10CH4 + O2 2C6H6 + 2C7H8 + C2H4
+ 2C + 32H2 + 2H2O
Safety and Environmental Impacts

Methane, ethylene and some compositions of other hydrocarbons are exposed to
oxygen in the process of OCM. However, hydrocarbons such as ethylene and
methane are explosive and asphyxiant. OCM carries out around 700C and in
this case at 740C. However, the auto-ignition temperature of methane is 580C.
The hydrocarbon products such as benzene, toluene and ethylene can result in
chronic damage to the heart or central nervous system.
benzene and toluene are noted as flammable at high temperatures, hazardous
and stable; Code 2-3-0. Naphthalene is noted as flammable at high
temperatures, highly toxic and stable; Code 2-2-0.
The waste materials including carbon dioxide must be released within the
acceptable limits of the local policies. If not, the wastes will affect the
environment. For example, carbon dioxide is one of the key global warming
gases and also causes acid rain. Should proper EPA standards be maintained,
minimum treat will be imposed to the environment.
Process 4 Overviews
Pros
Cons
Exothermic Reaction
Multi Step Conversion
High conversion of methane to

ethylene
Reaction occurs at high temperature

(740C)
High Selectivity towards ethylene
Temperature differences between the

reactors
Loss of materials due to multi stages
Catalytic deactivation due to high
temperature
8 | Appendix
III.5.5 Process 5: Integrated Process

Conversion Method
Type of Reaction
Mode
Catalyst
Status
:
:
:
:
:
:
1
Direct
Endothermic
Continuous
Mo/HZSM-5 & Mo2C/ZSM-5
Patented
Brief Overview
The integrated process is a combination of the direct dehydro-aromatization of
methane; Process 1 and the 3rd step in the OCM method; Process 4.
Process Description
Recyle
Shale Gas
Pre-Treatment of
Shale Gas
Methane
+
Ethane
Reactor 1
Methane
+
Ethane
Reactor 2
Benzene
+
By-products

carbon dioxide
Separator 1
Benzene Storage
Benzene
By-products
Separator 2
By-products
By-Products
Storage
This process is similar to that of Process 1 using Mo/HZSM-5 as a catalyst.

However instead of solely utilizing one catalyst to convert a majority of the
methane to benzene, this process also converts ethane to benzene using
MO2C/ZSM-5 as a catalyst much like, Reactor 3 in Process 4. Hence, by using
two reactors in series, the overall yield of the product can be maximized.
Process 1: *Methane Benzene
Process 4: Methane Ethene *Ethane Benzene
*refers to the main reactant that is converted to benzene
Overall Chemical Equation:
C H
2 6
CH4
2C6H6 + C10H8 + 2C7H8 + C3H6 + C2H4
+ C + H2
Refer to Section III.5.1 and III.5.4 for further details.
9 | Appendix
AI.4 Equipment Selection

Once Process 5 was selected, a detailed analysis was done before selecting the
major separation equipments; C3+ hydrocarbon separation unit, C6+ hydrocarbon
separation unit and hydrogen separation unit.
C3+ Hydrocarbon Separation Unit
In order to produce marketable products; propane, butane and pentane had to
be separated. The extracted C3+ hydrocarbons were then purified to be sold. The
equipments considered were cryogenic expansion separation and membrane
separation.
i.
Cryogenic Expansion
The cryogenic expansion separation method consists of dropping the

temperature of the gas stream to around -49 C (NaturalGas, 2015). The most
common method of chilling is using the turbo expander process. In this process,
external refrigerants are used to cool the natural gas stream. Then, an
expansion turbine rapidly expands the chilled gases, which causes the
temperature to drop. This rapid temperature drop condenses ethane and the C3+
hydrocarbons, while maintaining methane and ethane in gaseous form; which is
later removed using a flash vessel. This process allows for the recovery of about
90 to 95 percent of the methane and ethane originally in the gas stream
(NaturalGas, 2015).
ii.
C3+ Selective Membrane
A C3+ selective membrane separator consist of a column with a

polytrimethylsilylpropyne (PTMSP) membrane (A. Lokhandwala and L. Jacobs,
2000). The membrane permeates the smaller molecules (methane and ethane)
and rejects the C3+ hydrocarbons. The membrane material is selectively
permeable to C3+ hydrocarbons and uses the working principle of pressure
difference across the membrane. It has a removal efficiency of 80-90% and can
withstand high temperatures and pressures (A. Lokhandwala and L. Jacobs,
2000).
Hence, the membrane separator was selected as it requires lower maintenance
and consumes less energy. Overall the membrane separation was deemed
simpler as it is a purely physical process.
C6+ Hydrocarbon Separation Unit
The three main products with more than 6 carbons are benzene, naphthalene
and toluene. In order to prevent crystallisation of naphthalene in the system,
naphthalene is to be separated, prior to the separation of benzene and toluene
from the unreacted feed. Since the main products are to be purified to market
grades, further separation is mandatory. The equipments considered were
cryogenic distillation, absorption column and low temperature, high pressure
flash vessel.
i.
Cryogenic Distillation
In the cryogenic distillation process, the top part of the column would need to be
maintained at a temperature of -50oC or lower to separate methane from
10 | A p p e n d i x
benzene and toluene. It is a challenge to maintain such a low temperature.

ii.
Absorption Column
An absorption column using Exxon Mobil paraffin mixture Isopar G; absorption

solvent can absorb benzene and toluene from the unreacted feed gas. Then, the
products can be separated from the solvent in the solvent regeneration column.
However, an extra distillation column is required to further separate benzene
from toluene.
iii.
High Pressure Flash
In the low temperature, high pressure flash the stream entering is mostly in
liquid phase will enter a distillation column to reach the target purity. The
unreacted feed gas which leaves from the top of flash will then enter a pressure
swing adsorption unit to remove hydrogen before being recycled back to the
system. Low temperature and high pressure is favourable for adsorption and the
hydrogen recovered can be sold as side product.
Hence, the low temperature, high pressure flash with distillation columns were
selected as it has a lower operating cost, lower capital cost, doesnt require
additional chemicals and increases the gross profit earned.
H2 Separation Unit
The dehydroaromatization reactions produce a significantly large amount of
hydrogen gas. Hence, a hydrogen separation unit is essential to prevent
hydrogen accumulation. The equipments considered were a hydrogen selective
membrane separator and pressure swing absorption unit.
i.
Hydrogen Selective Membrane
A hydrogen selective membrane separator only allows hydrogen gas to pass

through since the atomic size is small as compared to the other components in
the stream. This membrane can achieve a purity of 99%. However, the set-backs
of membrane separator is that it is expensive since the membranes have to be
changed in 2 years and can only operate efficiently at low inlet flowrates.
ii.
Pressure Swing Absorption
The pressure swing absorption unit utilizes different layers of absorbents in

absorption columns where all other components are absorbed into the absorbent
materials (activated carbon, alumina and zeolites absorbent layers) while the
hydrogen gas will be collected from the top (Baksh et al., 2002). The absorption
cycle must operate at a high pressure condition in the range of 5-20 bars but
temperatures can be kept at room temperature of 30oC or lower(Baksh et al.,
2002). During the desorption process, the other components will be released
from the pores of the absorbents; known as hydrogen stripped gas
simultaneously reducing the pressure to 1atm. This proves that this technique is
more energy efficient since it does not require any heat utility input or removal.
Moreover, the purity of hydrogen gases is above 90% and can be sold at the
current market rate.
Hence, it advisable to use pressure swing absorption as it has a lower capital
cost and low maintenance. Pressure swing absorption is a conventional
technique that consumes less energy.
AI.5 Catalyst Selection

There are several suitable catalysts for the methane and ethane conversion to
benzene based on the selected Process 5. The most common catalysts are
mainly metal-zeolite catalysts. The four types of catalysts discussed are 0.5%
FeSiO2, Mo/HZSM-5, Mo2C/ZSM-5 and Re/ZSM-5.
i.
0.5% FeSiO2
Methane conversion using 0.5% FeSiO2 can reach up to 48.1% at 1363K.

However, selectivity towards the main product is lower compared to the side
products. For instance, selectivity of benzene ranges from 21.0% to 29.1% while
for ethylene it is 40.9% to 52.1% and naphthalene is 23.6% to 38.2%(Guo et al.,
2014).
The presence of ethane in the feed enhances the conversion of
methane but concurrently results in the formation of coke. The yields of ethylene,
benzene and naphthalene from methane conversion (at 1225K and atmospheric
pressure) were expected to be 9.0%, 34.0% and 57.0% at equilibrium. However,
if was found the reaction was unable to reach equilibrium after 60 hours. Lastly,
this catalyst is yet to be patented and results are based on lab scale tests.
ii.
Mo/HZSM-5
The catalyst Mo/HZSM-5 can catalyse both the methane and ethane conversion
to benzene whilst maintaining a high selectivity towards benzene. Selectivity
towards benzene for methane conversion ranges from 47.2% to 68.6% whereas
it ranges from 48.3% to 72.0% for the ethane conversion. (Su et al., 2003)
Methane conversion to benzene is low; 10.6% (Ma et al., 2000). The catalyst
needs to be regenerated due to the formation of coke. The selectivity of coke
was found to be approximately 12% to 26%. However, it is a more reliable
catalyst as extensive studies have been carried out. The use of this catalyst has
been patented by UOP LLC in 1991. Several patents can also be found to further
support both the methane and ethane conversion using Mo/HZSM-5. Different
types of reactors such as fixed-bed, moving bed and fluidized bed reactor can be
used.
iii.
Mo2C/ZSM-5
Mo2C/ZSM-5 is an effective catalyst to convert both methane and ethane to

benzene. Conversion of ethane is high compared to catalyst I, II and IV (67.2%).
The benzene selectively is also quite high at 30% (Solymosi and Szoke, 1998).
The methane conversion exhibits a high selectivity towards benzene (85.0%).
However, the conversion of it is low (5.0-10.0%). Carbon dioxide addition has a
detrimental effect to the catalytic properties of the catalyst. Based on
experiments, it was shown that higher yields can be achieved by using a
fluidized bed for methane conversion (Cook et al., 2009). Coke is produced from
the ethane conversion. The catalyst needs to be regenerated before it can be
used for the process.
iv.
Re/ZSM-5
Re/ZSM-5 converts both methane and ethane to benzene. At 873 K, conversion

of ethane can reach 48.0% with a benzene selectivity of 23.0%. Methane
conversion is high selectivity towards benzene (86.7%) (Slocum and Bhasin).
Ethylene will also be produced from this conversion (Solymosi and Tolmacsov).
In order to reduce the production of ethylene to subsequently enhance the yield
of benzene, two catalyst bed are requires. A significant amount of carbon

monoxide is produced in the reaction.
Hence, it was decided to capitalise on the idea to double the overall benzene
conversion by selecting two best catalysts to convert the two largest fractions of
the shale gas feed; methane and ethane to the desired product; benzene. Both
Mo/HZSM-5 and Mo2C/ZSM-5 are impressive catalysts which converts both
methane and ethane to benzene with high conversion rates and selectivity. The
use of these two different catalysts maximizes the benzene production.
AI.6 Safety Evaluation
Figure AI.3.1: Fire Diamond, NFPA 704.

Table AI.3.1: Fire Diamond Classification System (NFPA, 2015).
Flammability (red)
0
1
2
Non-combustable
Require preheating before ignition occurs
Needs to be heated under high ambient temperature before ignition
3
4
Ignites under all ambient temperatures

Readily vaporises at normal atmospheric pressure and temperatures
Health (blue)
No health threat
Minor irritation
Temporary residual injury
May cause serious or moderate residual injury
Death or major residual injury

Instability/Reactivity (yellow)
0
1
Stable even under fire exposure conditions

Unstable at elevated temperatures and pressures.
Violent chemical change at elevated temperatures and pressures.
Capable of detonation or explosion at elevated temperatures and pressu

res
Readily capable or detonation at normal conditions.
An indication using a code was used in the environmental evaluation (eg, Code
1-2-4 to represent a flammability of 1, health of 2 and instability/reactivity of 4).
AI.7 Economic Potential Evaluation
Table AI.7.1: Cost of Chemicals (ICIS, 2014)/(CHANTAL MARCHESI, 2015)/

(Indexmundi, 2015).
Chemical
Cost (USD/MT)
Methane
208.30
Ethane
91.50
Propane
Benzene
199.40
1473.00
Toluene
1201.60
Naphthalene
569.40
Ethene
1336.10
Acetylene
2204.60
Hydrogen
Water
1500.00
0.41
Xylene
Oxygen (Air)
Carbon Dioxide
Methanol
1200.00
0.00
15.00
473.86
Process 1 Reaction Path

Refer to Equation III.5.1.10
Table AI.7.2: Process 1 Gross Profit Calculation.
Reaction Path 1
CH4
Stoichiometric
(kmol)
C10H8
C3H6
C7H10
C2H4
H2
18
62
16.04
30.07
78.11
128.17
92.14
44.1
28.05
2.01
304.76
541.26
156.22
256.34
88.20
184.28
28.05
124.62
1.95
3.46
1.00
1.64
0.56
1.18
0.18
0.80
208.30
91.5
1373.00
549.40
199.40
1101.60
1336.10
1000.00
Product Ratio
(kg/kg C6H6)
Price (USD/MT)
C6H6
19
Molar Weight
(kg/kmol)
Weight (kg)
C2H6
*Coke is formed on the catalyst

Gross
(Process 1)
Profit = (Price x Product Ratio)Products - (Price x Product

Ratio)Reactants
= 4000.79 USD/MT
Table V AI.7.3: Process 2 Gross Profit Calculation.
Reaction Path 2
Stoichiometric
(kmol)
CH4
C2H2
C6H6
C2H6
C2H4
H2
Molar Weight
(kg/kmol)
16.04
26.04
78.11
30.07
28.05
2.01
Weight (kg)
96.42
26.04
78.11
30.07
28.05
12.06
1.23
0.33
0.38
0.36
0.15
Product Ratio
(kg/kg C6H6)
Price (USD/MT)
Gross
(Process 2)
208.30 2204.60 1373.00
91.50 1336.10 1000.00

Ratio)Reactants
= 1050.82 USD/M

Reaction Path 3
CH3OH
Stoichiometric
(kmol)
Molar Weight
(kg/kmol)
Weight (kg)
Product Ratio
(kg/kg C6H6)
Price (USD/MT)
Gross
(Process 3)
C6H6
C7H8
C8H10
H2
H2O
21
21
32.04
78.11
92.14
106.16
2.01
28.05
672.84
78.11
92.14
106.16
8.61
1.18
1.36
0.23
7.54
474.90 1373.00
1101.6
1200.00
1000.00
0.41
18.09 589.05

Ratio)Reactants
= 455.91 USD/MT

Integrated
Process
CH4
C2H
6
O2
C6H6
C7H8
C2H4
H2
H2O
Stoichiometric
(kmol)
10
10
32
Molar Weight
(kg/kmol)
16
30
31.99
78.1
92.1
28.1
2.01
18.02
Weight (kg)
160
301
31.99
156
184
28.1
64.32
36.04
Product Ratio
(kg/kg C6H6)
1.03
1.92
0.20
1.18
0.18
0.41
0.23
Price (USD/MT)
208
91.5
0.00
1373
1101
1336
1000
0.41
Gross
(Process 4)

Ratio)Reactants
= 4511.31 USD/MT

Integrated Process
Stoichiometric
(kmol)
Molar Weight
(kg/kmol)
Weight
(kg)
Product Ratio
(kg/kg C6H6)
Price
(USD/MT)
Gross Profit (Process 4)
CH4
C2H6
C6H6
C10H8
C3H6
C7H10
C2H4
H2
13.5
14.5
47.5
16.04
30.07
78.11
128.17
92.14
44.1
28.05
2.01
216.54
436.02
156.22
128.17
44.10
184.28
28.05
95.48
1.39
2.79
0.82
0.28
1.18
0.18
0.61
208.30
91.5
1373.00
549.40
199.40
1101.60
1336.10
1000.00
= (Price x Product Ratio)Products - (Price x Product Ratio)Reactants

= 3486.46 USD/MT
AI.8 Detail Calculation

Conversion of Feed
Feed Gas Data
Temperature, C
48.90
Pressure, kPag
6,000
Molar Flow, MMSCFD
20.00
Equation 1 is used to convert standard flow with unknown gas density:

Eq 1: Qactual=Qstandard*
Pstandard
Pactual
Tstandard
Tactual
R
Qstandard
Qactual
=
=
=
=
=
=
=
=
Pstandard
Tactual
* Tstandard
Pactual
(Neutrium, 2012)
1.01bar
61.0 bar
288 K
321.9 K
8.314 J K-1 mol-1
20 MMSCFD= 23543.447 m3/h
1.01325
321.9
23543.447* 61 * 288
437.105 m3/h
Using ideal gas equation:

PV=nRT
(6100000 Pa)(437.105 m3/h)= n (8.314 J/mol K) (321.9 K)
n=
(6100000 Pa)(437.105 m3/h)

(8.314 J/mol K) (321.9 K)
n = 996.286 kmol/h
Feed molar flow rate = 996.286 kmol/h
Component flowrate = Component mole fraction*Feed molar flowrate
Eg: Flowrate for CO2 = 0.00055*996.286 = 0.548 kmol/h
Table AI.8.1: Component Flowrate.
Components
CO2
N2
CH4
C2H6
C3H8
C4H10
C5H12
H2O
Mole Fraction
0.00055
0.00397
0.7621
0.14859
0.0533
0.02134
0.00641
0.00375
Component Flowrate(kmol/h)
0.548
3.955
759.270
148.038
53.102
21.261
6.386
3.736
Flash 1 (FV-101)
Equation 1:
Xi=( 1)+1
Equation 2:
Vi =fFi
Equation 3:
Di= yiVi
Operating condition of flash 1
Pressure
60.4bar
Temperature
30oC
-K values are obtained from HYSYS as high pressure is involved.

Table AI.8.2: Stream Molar Flowrate for FV-101.
Compone
nt
CO2
N2
CH4
C2H6
C3H8
C4H10
C5H12
H2O
Sum
S-02
(kmol
/h)
0.548
3.955
759.27
148.04
53.102
21.261
6.386
3.736
996.30
zi
0.001
0.004
0.762
0.149
0.053
0.021
0.006
0.004
Ki
54.54
1759.4
1027.7
1242.9
91.87
132.70
189.44
0.00
xi
0.000
0.000
0.001
0.000
0.001
0.000
0.000
0.999
xi=1
yi
0.001
0.004
0.764
0.149
0.053
0.021
0.006
0.002
yi=1
S-03
(kmol/h)
S-04
(kmol/h)
0.55
3.96
759.27
148.04
53.10
21.26
6.39
1.60
994.17
0.00
0.00
0.00
0.00
0.00
0.00
0.00
2.13
2.13
f= 0.998(1)
Vi
= 0.998*996.29= 994.17 kmol/h
Eg Calculation: DCH4(2)
= 0.764*994.17
= 759.27 kmol/h
; WCH4 = 759.27-759.27
= 0 kmol/h
(1)
Trial and error was done to guess the value of f until the both xi and yi equal to 1
(2)
DCO2 is CO2 flowrate in S-03.
Flash 2 (FV-102)
f= 0.982
Component
CO2
N2
CH4
C2H6
C3H8
C4H10
C5H12
H2O
C6H6
C10H8
C7H8
H2
C2H4
C3H6
Sum
Table AI.8.3: Stream Molar Flowrate for FV-102.

S-51
(kmol/h)
6.34
45.03
5677.51
79.61
69.07
11.89
1.76
0.00
148.46
7.79
5.98
901.83
12.79
0.07
6968.15
zi
0.001
0.006
0.815
0.011
0.010
0.002
0.000
0.000
0.021
0.001
0.001
0.129
0.002
0.000
1.000
Ki
4.327
92.432
21.258
4.330
0.702
0.236
0.080
0.000
0.007
0.000
0.002
293.149
5.314
0.690
xi
yi
0.0002
0.0001
0.0390
0.0027
0.0140
0.0068
0.0026
0.0000
0.8309
0.0606
0.0413
0.0004
0.0004
0.0000
1.000
0.0009
0.0066
0.8293
0.0116
0.0098
0.0016
0.0002
0.0000
0.0061
0.0000
0.0001
0.1318
0.0019
0.0000
1.000
S-52
(kmol/h)
6.31
45.03
5672.50
79.27
67.27
11.01
1.42
0.00
41.75
0.01
0.67
901.78
12.75
0.07
6839.84
S-53
(kmol/h)
0.03
0.01
5.01
0.34
1.80
0.88
0.34
0.00
106.71
7.78
5.31
0.06
0.05
0.00
128.30
Reactors
Equation 4:
Selectivity=
Moles of product formed

Moles of reactant consumed x Stoichiometric factor(3)
(Sinnott, Coulson and Richardson, 2005)

(3)
Stoichiometric factor = Moles of product formed per mole of reactant reacted in

the reaction stoichiometric equation. (Sinnott, Coulson and Richardson, 2005)
Reactor 2:
Table AI.8.4: Specifications of Reactor 2.
Catalyst
Reactant
Co
Mo2C/ZSM-5
Methane
Ethane
0.075
0.672
C2H6
0.1
0
C6H6
0.85
0.42
Selectivity
C2H4
C
0.05
0
0
0.02
C7H8
0
0.11
CH4
0
0.45
(Solymosi and Szoke, 1998)

Reactions:
1) 6 CH4 C6H6 + 9 H2
2) 2 CH4 C2H6 + H2
3) 2 CH4 C2H4 + 2 H2
4) 3 C2H6 C6H6 + 6 H2
5) C2H6 + H2 2 CH4
6) 7 C2H6 2 C7H8 + 13 H2
7) C2H6 2 C + 3 H2
Table AI.8.5: Stream Molar Flowrate for Reactor 2.

Components
CO2
N2
CH4
C2H6
C3H8
C4H10
C5H12
C6H6
C10H8
C7H8
H2
C2H4
C3H6
C
Total
S-42
(kmol/h)
6.34
45.03
6024.19
173.84
69.07
11.89
1.76
68.10
7.79
2.31
204.16
1.49
0.07
0.00
6616.05
Amount produces/reacted
(kmol/h)
0.00
0.00
-346.68
-94.23
0.00
0.00
0.00
80.36
0.00
3.67
697.68
11.30
0.00
4.67
S-44
(kmol/h)
6.34
45.03
5677.51
79.61
69.07
11.89
1.76
148.46
7.79
5.98
901.83
12.79
0.07
4.67
6972.82
Example calculation:
Benzene formed from methane and ethane conversion
1
= 0.075*(0.85*6024.19)*6 + 0.672*(0.42*173.84)*3
= 80.16 kmol/h
Recycle Loop
Equation 5:
Scale Residue (%) =
Calculated value-Estimated value

100% (Smith, 2005)
Estimated value
Figure AI.8.1: Simplified block diagram for recycle loop.
Iterations were done to estimate the values of S-87 and S-88 until the scale residue is less than 1%.
Table AI.8.6: Flowrate of each stream in recycle loop.
Overall Mass Balance

Component
Shale Gas
Benzene
Naphthalene
Toluene
Propane
Hydrogen
Yield of C6+ hydrocarbon=
Mass Flowrate(kg/h)
20872.21
8158.05
994.69
586.54
2067.18
1638.36
8158.05+994.69+586.54
*100%=46.7%
20872.21
Example Calculation For Comparison Between Manual Mass Balance

and HYSYS Simulation
Equation 6:
% Error=
100%
Eg: Stream S-01

Stream
S-01
% Error
Manual Calculation (kg/h)

20872.21
= |
(20872.2120872.64)
20872.21
Simulation (kg/h)
20872.64
| 100%
= 0.002 %
Calculation of HE-101
Table AI.8.7: Constant Value for Enthalpy Calculation.
Component
CH4
C2H6
C3H8
C4H10
C5H12
C6H6
C10H8
C7H8
H2
C2H4
C3H6
N2
CO2
a
4.568
4.178
3.847
5.5547
7.554
3.551
2.889
3.866
2.883
4.221
3.834
3.539
3.259
b x 103
-8.975
-4.427
5.131
5.536
-0.368
-6.184
14.306
3.558
3.681
-8.782
3.893
-0.261
1.356
c x 105
3.631
5.66
6.011
8.057
11.846
14.365
15.978
13.356
-0.772
5.795
4.688
0.007
1.502
d x 108
-3.407
-6.651
-7.893
-10.571
-14.939
-19.807
-23.93
-18.659
0.692
-6.729
-6.013
0.157
-2.374
e x 1011
1.091
2.487
3.079
4.134
5.753
8.234
10.173
7.69
-0.213
2.511
2.283
-0.099
1.056
Conditions of Inlet
Temperature (C)
Temperature (K)
Pressure
Condition of Outlet
48.9C
321.9K
61.0 Bar
Temperature (C)
Temperature (K)
Pressure
30 C
303 K
60.7 Bar
Enthalpy Calculation
T2 C
p
dH =
T1
dT
b
c
d
4 e
5
=R(a(T2 -T1 )+ (T2 -T1 )2 + (T2 -T1 )3 + (T2 -T1 ) + (T2 -T1 )
2
3
4
5
Where,
a,b,c,d and e
R
T1
T2
:
:
:
:
Constant value of each component

Gas constant (8.314 KJ/Kmol K)
Inlet Temperature (K)
Outlet Temperature (K)
(Poling, Prausnitz and O'Connell, 2015)
Example calculation for enthalpy of CH4

-3
dH(C3 H8 )= 4.178(321.9-303)-5
5.13110
2
(321.9-303)2
-8
-11
6.01110
7.89310
4 3.07910
(321.9-303)3 (321.9-303) +
3
4
5
(321.9-303)
dH(C3H8) = - 1446.33 kJ/hr

The rest of the components will follow the CH4 calculation.
Constant value for each component can be taken from table 1.
Latent Heat of Vaporisation

Lv =Lc,b [
Tc -T 0.38
]
Tc -Tb
Where,
Lv
: Latent Heat of Vaporization (Kj/Kmol)
Lc,b
: Latent Heat of Vaporization at boiling point (Kj/Kmol)
Tc
: Critical Temperature (K)
Tb
: Boiling Temperature (K)
(Sinnott, Coulson and Richardson, 2005)
Table AI.8.8: Data for latent heat calculation.

Component
Tc (K)
Boiling T (K)
Latent Heat of Vaporisation

(KJ/Kmol)
CH4
190.6
111.65
8185
C2H6
305.4
184.45
14717
C3H8
359.8
231.05
18786
C4H10
452.2
272.65
22408
C5H12
469.9
309.15
25791
CO2
304.2
194.65
17166
N2
126.2
77.35
5581
H2O
647.3
373.15
40683
Substitute all the data

Lv(CH4) (inlet)
Because it exceeds Tc
Lv(CH4) (outlet)
Because it exceeds Tc
Lv(C3H8) at inlet temperature

Lv(C3H8) inlet = 18786((359.8-321.9)/(359.8-231.05))0.38
= 11803.57 kJ/kmol
Lv(C3H8) at outlet temperature

Lv(C3H8) outlet = 18786((359.8-303)/(359.8-231.05))0.38
= 13765.21 kJ/kmol
Take the value of average Lv

Lv(C3H8) average
= (11803.57+13765.21)/2
= 12784.38 kJ/kmol
*The steps for all the components are the same

Calculation of Heat of Duty from inlet and Heat of Condensation
Qv =mLv
Q=minlet dH
Where
m
Lv
Qv
Q
dH
=Liquid Molar Flow (kmol/hr)

= Latent Heat of Vaporisation (KJ/kmol)
= Heat Duty of Vaporization (KJ/hr)
= Heat duty of inlet (KJ/hr)
= Enthalpy of the component (KJ/hr)
Example Calculation for C3H8

Q
=53.10(-1466.33)
=-76803.05 KJ/hr
Qv
=11.40(12784.39)
=145707.88 KJ/hr
Since the liquid is produced from the condensation of the vapour, thus
=
Q total
= Q- Qv
= -22510.93 KJ/hr
= -61.81 KW
Q total for HE-101
= -412.12 kW
Repeat the calculation and sum up the total heat duty for every component. The
results for Heat Duty for heat exchanger are listed in the report. For cooler, the
sign of the heat duty will be minus due to energy released. On the other hand,
the sign of heater will be positive due to energy that needs to be supplied.
HE-110 and HE-114 will follow the calculation steps above and the rest of the
heat exchanger will also follow the steps above without the addition of the heat
of vaporization.
Calculation for TB-101

Conditions of Inlet
Temperature (C)
Temperature (K)
Pressure
Condition of Outlet
57.3C
330.3 K
59.9bar
Temperature (C)
Temperature (K)
Pressure
30 C
303 K
30.7bar
Steps:
Cp average for every components is taken based on (Cp inlet + Cp outlet)/2
Cp inlet and outlet is calculated based on the formula below
Cp
=a+bT+cT2 +dT3 +eT4
R
The table for the constant can be taken from the table in HE-101 calculation
section.
Adiabatic exponent need to be calculated for expansion calculation

=
Cp
CV
Cv =Cp -8.314
is specific heat capacity at constant pressure (KJ/kmol K)
is specific heat capacity at constant volume (KJ/kmol K)
Table AI.8.9: Cp and Cv Value Calculated.
Components
Mole Fraction
Cp
inlet
Cp
Outlet
Cp
Average
Cv
Average
CH4
C2H6
C3H8
C4H10
C5H12
CO2
N2
H2O
0.7938
0.1458
0.0437
0.0108
0.0014
0.0006
0.0042
0.0001
37.14
56.45
80.00
106.89
130.18
38.38
29.14
33.73
35.97
53.15
74.69
100.08
121.78
37.23
29.11
33.54
36.55
54.80
77.35
103.48
125.98
37.80
29.13
33.64
28.24
46.49
69.03
95.17
117.66
29.49
20.81
25.32
*Note: All Cp and Cv values are in kJ/kmol K

The total Cp mixture can be calculated by the summation of mole fraction times
the Cp average for every component.
Cp mixture = mole fraction x Cp average

Cv mixture = mole fraction x Cv average
Cp mix calculated is 41.84 kJ/kmol K and Cv mix calculated is 33.52 kJ/Kmol K
Adiabatic Exponent calculated is 1.25
Polytropic Exponent is calculated by
k-1
k
=np -1
(Gicquel, 2011)
Where
np is polytropic efficiency
is adiabatic exponent
k is polytropic exponent
Polytropic efficiency calculated is 1.15
For EX-101, estimation of inlet temperature is used. Using the formula below,
the actual inlet temperature can be calculated and will be used.
T2
=
T1
k-1
P
k
( 2)
P1
(Gicquel, 2011)
Where
T2 is outlet temperature (K)
T1 is inlet temperature (K)
P2 is outlet pressure (bar)
P1 is inlet pressure (bar)
Actual inlet temperature calculated is 57.3 C
The actual inlet temperature that has been calculated, will be used for the
calculation of the work done by the fluid.
W=-m(H2 -H1 )
W=-mdH
Where
W is work done
m is molar flow (Kmol/hr)
dH is enthalpy (KJ/Kmol)
The steps of calculate the enthalpy is referring back to HE-101 calculation. It is

the same method.
Table AI.8.10: Work done calculated of each component.

Mole Flow
(Kmol/hr)
753.25
138.37
41.51
10.29
1.36
0.54
3.94
0.05
Components
CH4
C2H6
C3H8
C4H10
C5H12
CO2
N2
H2O
W total
W total
Enthalpy
(KJ/Kmol)
998.98
1497.83
2114.32
2828.74
3443.59
1033.37
796.21
919.42
Work done
(KJ/hr)
752483.33
207253.88
87758.64
29094.81
4700.36
560.50
3135.66
48.03
= summation of the work done by each component

= 1085035.30 KJ/hr
= 301.40 KW
Since expander will generate electricity thus the heat released is -301.40 KW
(minus sign shows the expander release energy).
The rest of the expanders will follow the steps above.
Calculation for C-101

Conditions of Inlet
Temperature (C)
Temperature (K)
Pressure
Condition of Outlet
43.0 C
316 K
1.1 bar
Temperature (C)
Temperature (K)
Pressure
152.0 C
425 K
3 bar
Steps:
Cp average for every components is taken based on (Cp inlet + Cp outlet)/2
Cp inlet and outlet is calculated based on the formula below
Cp
=a+bT+cT2 +dT3 +eT4
R
The table for the constant can be taken from the table in HE-101 calculation
section
Adiabatic Exponent need to be calculated for calculation of expansion process

=
Cp
CV
Cv =Cp -8.314
Cp is specific heat capacity at constant pressure (kJ/kmol K)
Cv is specific heat capacity at constant volume (kJ/kmol K)
Table AI.8.11: Cp and Cv Value Calculated.
Components
CH4
C2H6
C3H8
C4H10
C5H12
C6H6
C10H8
C7H8
H2
C2H4
C3H6
N2
CO2
Mole Fra
ncti
0.81478
0.01142
0.00991
0.00171
0.00025
0.02131
0.00112
0.00086
0.12942
0.00184
0.00001
0.00646
0.00091
Cp
inlet
Cp
Outlet
Cp
Average
Cv Average
36.51
54.71
77.21
103.31
125.76
87.40
139.91
109.80
28.87
44.56
67.14
29.13
37.77
41.98
68.32
98.26
130.36
159.50
119.17
189.16
146.89
29.22
54.90
83.77
29.34
42.14
39.24
61.52
87.74
116.84
142.63
103.29
164.54
128.34
29.05
49.73
75.46
29.23
39.96
30.93
53.20
79.42
108.52
134.32
94.97
156.22
120.03
20.73
41.42
67.14
20.92
31.64
*Note: All Cp and Cv values are in kJ/Kmol K

Cp mixture = mole fraction x Cp average
Cv mixture = mole fraction x Cv average
Cp mix calculated is 40.10KJ/Kmol K and Cv mix calculated is 31.79 KJ/Kmol K
Adiabatic Exponent calculated is 1.26
Polytropic Exponent is calculated by
np
k-1
k
Where
np is polytropic efficiency
is adiabatic exponent
Polytropic efficiency calculated is 1.34
For C-101, estimation of outlet temperature is used. Using the formula below,
the actual inlet temperature can be calculated and will be used.
T2
=
T1
k-1
k
(P2)
1
Where
T2 is outlet temperature (K)
T1 is inlet temperature (K)
P2 is outlet pressure (bar)
P1 is inlet pressure (bar)
Actual outlet temperature is 151.5 C
This actual inlet temperature that has been calculated, will be used for the
calculation of the work done by the fluid.
W=-m(H2 -H1 )
W=-mdH
Where
W is work done
m is molar flow (Kmol/hr)
dH is enthalpy (KJ/Kmol)
The steps of calculate the enthalpy is referring back to HE-101 calculation. It is
the same method.
Table AI.8.12: Work done calculated of each component.
Enthalpy
Work done
Components
mF (kmol/hr)
(kJ/Kmol)
(kJ/hr)
CH4
5677.51
-4246.94
-24112081.91
C2H6
79.61
-6668.71
-530890.50
C3H8
69.07
-9523.38
-657749.75
C4H10
11.89
-12681.39
-150780.51
C5H12
1.76
-15475.46
-27237.80
C6H6
148.46
-11221.28
-1665951.27
C10H8
7.79
-17891.09
-139455.58
C7H8
5.98
-13943.22
-83353.89
H2
901.83
-3154.57
-2844902.24
C2H4
12.79
-5388.87
-68925.14
C3H6
0.07
-8188.93
-592.83
N2
45.03
-3169.89
-142754.49
CO2
6.34
-4339.84
-27504.92
W total
W total
= summation of the work done by each component

= -30452180.84 kJ/hr
= -8458.94 kW
Since compressor will need to energy to compress the fluid to higher pressure
thus the heat supplied is 8458.94 kW (positive sign shows the compressor need
energy)
The rest of compressors will follow the calculation step above.
Calculation of PM-101
Conditions of Inlet
Temperature (C)
Temperature (K)
Pressure
Condition of Outlet
43.9C
316.9K
15.0bar
Temperature (C)
Temperature (K)
Pressure
44.4 C
317.4K
15.4 Bar
The work done by pump can be calculated from

W=VdP
dP is the pressure difference (bar)
V is volume (m3)
In order to calculate the volume, density for every component in the stream
need to be found.
C4
T
(1+1-( )
C3
=C1/C2
(Perry, Green and Maloney, 1984)

Where
is density of component (kg/m3)
C1,C2,C3, and C4 are constant value
T is inlet temperature (K)
Table AI.8.13: Constant Value for Density Calculation.
Components
CH4
C2H6
C3H8
C4H10
C5H12
C6H6
C10H8
C7H8
H2
C2H4
C3H6
N2
CO2
C1
2.9214
1.9122
1.3757
1.0677
0.8495
1.0162
0.6167
0.8488
5.4140
2.0961
1.4094
3.2091
2.7680
C2
0.28976
0.27937
0.27453
0.27188
0.26726
0.26550
0.25473
0.26655
0.34893
0.27657
0.26465
0.28610
0.26212
C3
190.56
305.32
369.83
425.12
469.70
526.16
748.35
591.80
33.19
282.34
365.67
126.20
304.21
C4
0.28881
0.29187
0.29359
0.28688
0.27789
0.28212
0.27355
0.2878
0.2706
0.2915
0.2950
0.2966
0.2908
In PM-101 only has 3 components, thus

Table AI.8.14: Volumetric Flowrate for components of PM-101.
Components
C3H8
C4H10
C5H12
Liquid Molar Flow

(kmol/hr)
99.65
2.47
0.00
Density
(kmol/m3)
5.46
3.44
2.70
Volumetric flowrate
(m3/hr)
18.78
0.70
0.00
*Note: Volumetric Flowrate = Liquid Molar Flow/Density

Total Volumetric Flowrate
= 19.48 m3/hr
Pressure Difference
= 0.4 bar
= 40 Kpa
Total Work Done
= VdP
= 779115.84J/hr
= 0.22KW
Pump efficiency
Thus, actual work done
= 0.75
= 0.29KW
The rest of the pumps will follow the calculation steps above.
Calculation of CR-101
Table AI.8.15: Energy Released at CR-101.
Components
Mole
Fraction
mF
(mol/h)
Latent
Heat of
Fusion
(kJ/mol)
Enthalpy
(kJ/kmol)
Energy
Released
(kJ/h)
Naphthalene
0.99
7782.00
18.99
11523.11
199141.39
Latent Heat of Fusion, HFusion (kJ/mol) for Naphthalene (GmbH, 2015)

(Heat contributed by toluene is not taken into account since it is less than 1%
mole composition)
Therefore, energy released by crystallizer-101:
Q
= (Molar Flowrate Latent Heat of Fusion) + (Molar Flowrate Enthalpy)

= (199141.39)/3600)
= 54.76 kW
Calculation of RX-102
Reactor-102 is a fluidized fixed bed reactor therefore the temperature of the inlet
and outlet stream is assumed to be the same.
Overall Energy Balance Equations on Reactor:

H=Reactions i Hreaction +nout Hout - nin Hin
Since, isothermal condition is applied, therefore nout Hout - nin =0
Table AI.8.16: Calculated Values for Net Heat of Formation for Each Reaction
(Methane Conversion).
Methane Conversion Table
Hf,
Reactants
1
(kJ/kmol)
Hf,
Products
1
(kJ,kmol)
Hf,
Reactants
2 (kJ/k
mol)
Hf,
Products
2
(kJ,kmol)
Hf,
Reactants
3
(kJ/kmol)
Hf,
Products
3
(kJ,kmol)
-149700.00
-84670
-449100
82930
-149700
52580
1 =
1.97
2 =
5.57
3 =
0.98
Net Hf, 1 (kJ/hr)
Net Hf, 1 (kJ/hr)
Net Hf, 1 (kJ/hr)
1469074.663
34053668.78
2284825.641
Table AI.8.17: Calculated Values for Net Heat of Formation for Each Reaction (Ethane Conversion).
Ethane Conversion Table
Heat of
Heat of
Heat of
Heat of
Heat of
Heat of
Formation, Formation, Formation, Formation,
Formation,
Formation,
Reactants
Products
Reactants
Products
Reactants
Products
1
1
2
2
3
3
(kJ/kmol) (kJ,kmol) (kJ/kmol) (kJ,kmol)
(kJ/kmol)
(kJ,kmol)
Heat of
Formation,
Reactants
4
(kJ/kmol)
Heat of
Formation,
Products
4
(kJ,kmol)
-254010.00
82930
-84670
-149700
-592690
100000
-84670
1 =
8.18
2 =
52.57
3 =
1.65
4 =
2.34
Net Hf, 2 (kJ/hr)
Net Hf, 2 (kJ/hr)
Net Hf, 2 (kJ/hr)
Net Hf, 2 (kJ/hr)
3433396.178
-3418513.521
1271582.661
197820.1786
Example Calculation
Q
= Reactions i Hreaction
= 39291854.58
= 1183.19 kW
AI.8 Reference
1. Poling, B., Prausnitz, J. and O'Connell, J. (2015). Properties of Gases and
Liquids. 5th ed. McGraw-Hill Education: New York, Chicago, San Francisco,
Athens, London, Madrid, Mexico City, Milan, New Delhi, Singapore, Sydney,
Toronto.
2. Agility Refrigeration Sdn Bhd. (2016). Comparison between refrigerants (a
mmonia vs freon). [online] Available at: http://agilityrefrigeration.weebly.c
om/information/comparison-between-refrigerants-ammonia-vs-freon [Access
ed 15 Apr. 2016].
3. ChemPub. (2016). Agenda Pub. [online] Available at: https://www.okc.gov/
AgendaPub/cache/2/ly5jglyeewioxs45oudjac45/13544880408201609040952
6.PDF [Accessed 15 Apr. 2016].
4. Guidechem.com. (2016). CAS 87842-32-8 POLY(TRIMETHYLSILYL)PROPYNE
Properties,manufacturers,suppliers,fob price. [online] Available at: http://
www.guidechem.com/cas-878/87842-32-8.html [Accessed 15 Apr. 2016].
5. ICIS. (2016). Global Assets. [online] Available at: http://www.icis.com/glob
alassets/global/icis/pdfs/sample-reports/chemicals-ethanolamines.pdf [Acces
sed 15 Apr. 2016].
6. Katalco Import. (2016). Zauba. [online] Available at: https://www.zauba.co
m/import-katalco-hs-code.html [Accessed 15 Apr. 2016].
7. Massenergy.org. (2016). Check Oil Prices, Heating Oil MA, Discount Heatin
g Oil MA, energy MA | Mass Energy. [online] Available at: https://www.ma
ssenergy.org/heating-oil/dhos/prices [Accessed 15 Apr. 2016].
8. Osha.gov. (2016). Silica eTool - Protection: Economics of Aluminum Oxide
as a Silica Substitute. [online] Available at: https://www.osha.gov/dsg/eto
ols/silica/protect_against/costcompare/costcompare.html [Accessed 15 Apr.
2016].
9. Saiadsorbents.com. (2016). Silica Prices. [online] Available at: http://www.
saiadsorbents.com/silicaprices.htm [Accessed 15 Apr. 2016].
10.Zeoliteproducts. (2016). Zeolite Products. [online] Available at: http://www
.zeolite-products.com/ktml2/files/uploads/zeolites.pdf [Accessed 15 Apr. 20
16].

11.Deloitte. (2016). Taxation and Investment in China. [online] Available at:
http://www2.deloitte.com/content/dam/Deloitte/global/Documents/Tax/dttltax-chinaguide-2015.pdf [Accessed 8 Apr. 2016].
12.Sinnott, R., Coulson, J. and Richardson, J. (2005). Chemical engineering
design. Oxford: Elsevier Butterworth-Heinemann.
13.Gicquel, R. (2011). Energy systems. Boca Raton: CRC Press.
14.GmbH, D. (2015). Heat of Fusion of Naphthalene from Dortmund Data Bank.
[online] Ddbst.com. Available at:
http://www.ddbst.com/en/EED/PCP/HFS_C123.php [Accessed 22 Nov. 2015].
15.Huvard, G., Felder, R. and Rousseau, R. (2005). Elementary principles of
chemical processes. New York: Wiley.
16.Perry, R., Green, D. and Maloney, J. (1984). Perry's Chemical engineers'
handbook. New York: McGraw-Hill.
17.Neutrium.net, (2012). Conversion of Standard Volumetric Flow Rates of Gas
Neutrium. [online] Available at:
https://neutrium.net/general_engineering/conversion-of-standardvolumetric-flow-rates-of-gas
18.Anwaer MaimaitimingRuiDAI. (2013). Study of the Natural Disaster
Vulnerability Evaluation in Aksu Prefecture, Xinjiang. Gansu Province:
JOURNAL OF GLACIOLOGY AND GEOCRYOLOGY.
19.Anon., 2010. McNichols: Industrial Architectural Hole Product Solution Since
1952. [Online]
Available at: http://www.mcnichols.com/?pageCode=pipedims
[Accessed 7 March 2016].
20.Anon., 2016. European Commission - Basics. [Online]
Available
at:
http://ec.europa.eu/environment/basics/greeneconomy/resources/index_en.htm
[Accessed 11 April 2016].
21.Anwaer Maimaitiming, D. R., 2013. Study of the Natural Disaster Vulnerability
Evaluation in Aksu Prefecture, Xinjiang, Gansu Province: JOURNAL OF
GLACIOLOGY AND GEOCRYOLOGY.
22.Arcadis, 2014. International Construction Costs Report: What will it mean for
2015, Amsterdam: ARCADIS.
23.Bambrick, W. E., 1987. U.S.A, Patent No. 785185.
24.Bloomberg New Energy Finance, 2014. Climatescope. [Online]
Available at: http://global-climatescope.org/en/country/china/#/details
[Accessed 16 11 2015].
25.Bosko Josimovic, J. P. &. S. M., 2014. The Use of the Leopold Matrix in
Carrying Out the EIA for Wind. Energy and Environment Research; Vol. 4, No.

1, pp. 43-54.
26.C. David Copper, F. A., 2014. Air Pollution Control: A Design Approach. Long
Grove: Waveland Press, Inc..
27.Ceresana, 2014. Ceresana. [Online]
Available
at:
studies/chemicals/benzene/
[Accessed 10 11 2015].
Available
at:
studies/chemicals/toluene/
[Accessed 10 11 2015].
http://www.ceresana.com/en/market-
http://www.ceresana.com/en/market-
29.CHANTAL MARCHESI, 2015. prweb. [Online]

Available at: http://www.prweb.com/releases/2015/10/prweb13014228.htm
[Accessed 17 11 2015].
30.Cheng-Hsiu Yu, C.-H. H. C.-S. T., 2012. A Review of CO2 Capture by
Absorption and Adsorption, Hsinchu: Taiwan Association for Aerosol Research.
31.CO2 Capture Project, 2008. CCP. [Online]
Available
at:
http://www.co2captureproject.org/pdfs/3_basic_methods_gas_separation.pdf
[Accessed 19 11 2015].
32.Colin F. Alie, 2004. CO2 Capture With MEA: Integrating the Absorption
Process and Steam Cycle of an Existing Coal-Fired Power Plant, Ontario:
University of Waterloo.
33.Commodity Data Group, 2015. Sun Sirs. [Online]
Available at: http://www.sunsirs.com/uk/sectors-14.html
[Accessed 17 11 2015].
34.Dale , B. D., 2014. Area Development. [Online]
Available at: http://www.areadevelopment.com/archive/Q4-2014.shtml
[Accessed 11 11 2015].
35.Dallas, 2014. Marekt Watch. [Online]
Available
at:
http://www.marketwatch.com/story/benzene-consumptionmarket-worth-534329-kilotons-by-2018-2014-05-31
[Accessed 13 11 2015].
36.David Netzer, 2003. Benzene Recovery from Refinery Sources by Coproduction of Olefins. Texas, NPRA.
37.EIA U.S. Energy Information Administration, 2015. International energy data
and analysis, Washington: U.S. Energy Information Administration.
38.EIA, 2014. U.S. Energy Information Administration. [Online]
Available at: http://www.eia.gov/todayinenergy/detail.cfm?id=14431

[Accessed 28 October 2015].
39.EIA, 2015. EIA U.S. Energy Infromation Administration. [Online]
Available
at:
http://www.eia.gov/beta/international/analysis_includes/countries_long/Chin
a/china.pdf
[Accessed 15 11 2015].
40.Enrique Iglesia, L. L. R. W. B., 2002. Design and Optimization of Catalyst and
Membrane Reactors for the Non-Oxidative Conversion of Methane. Chemical
Engineering Science (Edition: 57), pp. 4595-4604.
41.EPA, 2016. United States Environmental Protection Agency (EPA)-Air Toxic
Websites: Naphthalene. [Online]
Available at: https://www3.epa.gov/airtoxics/hlthef/naphthal.html
42.Gwynn Guilford, 2014. China has more shale gas than any other country. But
getting it out of the ground could be disastrous. [Online]
Available
at:
http://qz.com/258776/china-has-more-shale-gas-than-anyother-country-but-getting-it-out-of-the-ground-could-be-disastrous/
[Accessed 17 11 2015].
43.Hutchings, J. J. S. &. G., 2013. Catalytic Aromatization of Methane. London:
Royal Society of Chemistry.
44.ICIS, 2007. ICIS. [Online]
Available
at:
http://www.icis.com/resources/news/2007/11/07/9076550/toluene-usesand-market-data/
[Accessed 17 11 2015].
Available at: http://www.icis.com/resources/news/2015/10/30/9938846/usnov-benzene-increase-among-smallest-in-2015/
[Accessed 17 11 2015].
46.iHS, 2013. iHS. [Online]
Available at: https://www.ihs.com/products/toluene-chemical-economicshandbook.html
[Accessed 09 11 2015].
Available
at:
https://www.ihs.com/products/naphthalene-chemicaleconomics-handbook.html
[Accessed 10 11 2015].
Available at: https://www.ihs.com/products/benzene-chemical-economicshandbook.html
[Accessed 10 11 2015].

49.Jack G Calvert, R. G. D. J. J. O. G. S. T. &. T. J. W., 2008. Mechanisms of
Atmospheric Oxidation of the Alkanes. New York: Oxford University Press.
50.Kermanshahi pour, A. K. D. M. A., 2006. Kinetic Modelling of the
Biodegradation of the Aqeous P-Xylene in the Immobilized soil bioreactor.
BioChem. Engineering , pp. 204-211.
51.King, E. &., 2005. International Network for Environmental Management.
[Online]
Available at: http://www.inem.org/default.asp?Menue=6
52.Kristin Eberhard, 2014. Sightline. [Online]
Available at: http://www.sightline.org/2014/11/17/all-the-worlds-carbonpricing-systems-in-one-animated-map/
[Accessed 13 11 2015].
53.Levi, E. H. &. P. E., 1997. A Textbook of Modern Toxicology 2nd Edition.
Stamford, Connecticut: Appleton & Lange.
54.M. Baerns, L. M. H. Z., 1993. Oxidative Coupling of Methane To C2+
Hydrocarbons, Brussels: COMMISSION OF THE EUROPEAN COMMUNITIES.
55.Market Watch,, 2015. Market Watch. [Online]
Available
at:
http://www.marketwatch.com/story/platts-globalpetrochemical-prices-up-10-in-april-from-month-ago-2015-05-11
[Accessed 17 11 2015].
56.Masel, R. I., 2001. Chemical Kinetics & Catalysis. s.l.:Wiley-Interscience; 1
edition.
57.Merchant Research & Consulting ltd, 2015. Benzene: 2015 World Market
Outlook and Forecast up to 2019, Birmingham: Merchant Research &
Consulting ltd.
58.N.Palmeri, S. J., 2008. CARBON DIOXIDE ABSORPTION BY MEA. In: Journal
of Thermal Analysis and Calorimetry. Vol.91 ed. Dordrecht: Akadmiai Kiad,
Budapest, p. 8791.
59.Nation Master, ., 2012. Nation Master. [Online]
Available at: http://www.nationmaster.com/country-info/stats/Labor/Salariesand-benefits/Hourly-minimum-wage
60.Ohlen, K. C. Y. H. W. Y. C. L. S., 2005. Enchanced Degradation of Chlorinated
Ethylenes in Ground Water from a Paint Contaminated Site by Two-StageFluidized Bed Reactor. Chemosphere 58 (3), pp. 373-377.
61.Platts McGraw hill Financial,, 2014. Platts McGraw hill Financial. [Online]
Available
at:
http://www.platts.com/newsfeature/2014/petrochemicals/pgpi/benzene
[Accessed 17 11 2015].

62.Quotent, 2015. Latest Price Naphtha, Mannheim: Quotent.
63.Sayre, R., 2010. Microalgae: The Potential for Carbon Capture. BioScience, pp.
722-727.
64.Scott Stevens, K. M., 2013. Technically Recoverable Shale Oil and Shale Gas
Resources: An Assessment of 137 Shale Formations in 41 Countries Outside
the United States, Virginia: U.S. Energy Information Administration.
65.Scott, F. H., 2010. Professional Reference Shelf: Elements of Chemical
Reaction Engineering 5th Edition. [Online]
Available
at:
http://www.umich.edu/~elements/5e/03chap/profcollision.html#_ftn2
[Accessed 20 2 2016].
66.Sean, D., 2008. iHS. [Online]
Available at: http://chemical.ihs.com/nl/Public/2009/0905/0905.html
[Accessed 13 11 2015].
67.Slke, W., 2008-2016. Explore the World of Piping. [Online]
Available
http://www.wermac.org/equipment/storage_tanks_vessels_general.html
[Accessed 14 April 2016].
at:
68.Sunsirs, 2015. Sun Sirs. [Online]

[Accessed 17 11 2015].
69.U.S. Department of Energy, 2015. EIA. [Online]
Available
at:
http://www.eia.gov/electricity/monthly/epm_table_grapher.cfm?t=epmt_5_3
[Accessed 17 11 2015].
70.Van Hamme, J. S. A. W. O., 2003. Recent Advances in Petroleum Microbiology.
Microbiol.Mol.Biol.Rev 67 (4), pp. 503-549.
71.Vidali, M., 2001. Bioremediationan overview. Pure Appl. Chem. 73 (7), p.
11631172.
72.Woods, P. D. R., 2007. Rules of Thumb in Engineering Practice. s.l.:Wiley.
73.World Bank, 2014. Putting a price on carbon with a tax, Washington: World
bank.
74.WORLD HEALTH ORGANIZATION, 2002. IARC MONOGRAPHS ON THE
EVALUATION OF CARCINOGENIC RISKS TO HUMANS. France, IARCPress.
75.Wu, D., 2013. ICIS. [Online]
Available
at:
http://www.icis.com/resources/news/2013/01/11/9630910/market-outlookchina-petrochemical-capacity-to-expand-in-2013/
[Accessed 13 11 2015].
76.EIA U.S. Energy Information Administration. (2015). International energy

data and analysis. Washington: U.S. Energy Information Administration.
77.Gwynn Guilford. (2014, 09 02). China has more shale gas than any other
country. But getting it out of the ground could be disastrous. Retrieved 11 17,
2015, from Quartz: http://qz.com/258776/china-has-more-shale-gas-thanany-other-country-but-getting-it-out-of-the-ground-could-be-disastrous/
78.Scott StevensMoodheKetih. (2013). Technically Recoverable Shale Oil and
Shale Gas Resources: An Assessment of 137 Shale Formations in 41
Countries Outside the United States. Virginia: U.S. Energy Information
Administration.
79.Anwaer Maimaitiming, D. R., 2013. Study of the Natural Disaster Vulnerability
Evaluation in Aksu Prefecture, Xinjiang, Gansu Province: JOURNAL OF
GLACIOLOGY AND GEOCRYOLOGY.
80.Arcadis, 2014. International Construction Costs Report: What will it mean for
2015, Amsterdam: ARCADIS.
81.Bloomberg New Energy Finance, 2014. Climatescope. [Online]
Available at: http://global-climatescope.org/en/country/china/#/details
[Accessed 16 11 2015].
Available at: http://www.ceresana.com/en/marketstudies/chemicals/benzene/
[Accessed 10 11 2015].
Available at: http://www.ceresana.com/en/marketstudies/chemicals/toluene/
[Accessed 10 11 2015].
84.CHANTAL MARCHESI, 2015. prweb. [Online]
Available at: http://www.prweb.com/releases/2015/10/prweb13014228.htm
[Accessed 17 11 2015].
85.Cheng-Hsiu Yu, C.-H. H. C.-S. T., 2012. A Review of CO2 Capture by
Absorption and Adsorption, Hsinchu: Taiwan Association for Aerosol Research.
86.CO2 Capture Project, 2008. CCP. [Online]
Available at:
http://www.co2captureproject.org/pdfs/3_basic_methods_gas_separation.pdf
[Accessed 19 11 2015].
87.Colin F. Alie, 2004. CO2 Capture With MEA: Integrating the Absorption
Process and Steam Cycle of an Existing Coal-Fired Power Plant, Ontario:
University of Waterloo.

88.Commodity Data Group, 2015. Sun Sirs. [Online]
[Accessed 17 11 2015].
89.Dale , B. D., 2014. Area Development. [Online]
Available at: http://www.areadevelopment.com/archive/Q4-2014.shtml
[Accessed 11 11 2015].
90.Dallas, 2014. Marekt Watch. [Online]
Available at: http://www.marketwatch.com/story/benzene-consumptionmarket-worth-534329-kilotons-by-2018-2014-05-31
[Accessed 13 11 2015].
91.David Netzer, 2003. Benzene Recovery from Refinery Sources by Coproduction of Olefins. Texas, NPRA.
92.EIA U.S. Energy Information Administration, 2015. International energy data
and analysis, Washington: U.S. Energy Information Administration.
93.EIA, 2014. U.S. Energy Information Administration. [Online]
Available at: http://www.eia.gov/todayinenergy/detail.cfm?id=14431
94.EIA, 2015. EIA U.S. Energy Infromation Administration. [Online]
Available at:
http://www.eia.gov/beta/international/analysis_includes/countries_long/Chin
a/china.pdf
[Accessed 15 11 2015].
95.Gwynn Guilford, 2014. China has more shale gas than any other country. But
getting it out of the ground could be disastrous. [Online]
Available at: http://qz.com/258776/china-has-more-shale-gas-than-anyother-country-but-getting-it-out-of-the-ground-could-be-disastrous/
[Accessed 17 11 2015].
Available at:
http://www.icis.com/resources/news/2007/11/07/9076550/toluene-usesand-market-data/
[Accessed 17 11 2015].
Available at: http://www.icis.com/resources/news/2015/10/30/9938846/usnov-benzene-increase-among-smallest-in-2015/
[Accessed 17 11 2015].
Available at: https://www.ihs.com/products/toluene-chemical-economicshandbook.html
[Accessed 09 11 2015].

Available at: https://www.ihs.com/products/naphthalene-chemicaleconomics-handbook.html
[Accessed 10 11 2015].
100. iHS, 2014. iHS. [Online]
Available at: https://www.ihs.com/products/benzene-chemical-economicshandbook.html
[Accessed 10 11 2015].
101. Kristin Eberhard, 2014. Sightline. [Online]
Available at: http://www.sightline.org/2014/11/17/all-the-worlds-carbonpricing-systems-in-one-animated-map/
[Accessed 13 11 2015].
102. M. Baerns, L. M. H. Z., 1993. Oxidative Coupling of Methane To C2+
Hydrocarbons, Brussels: COMMISSION OF THE EUROPEAN COMMUNITIES.
103. Market Watch,, 2015. Market Watch. [Online]
Available at: http://www.marketwatch.com/story/platts-globalpetrochemical-prices-up-10-in-april-from-month-ago-2015-05-11
[Accessed 17 11 2015].
104. Merchant Research & Consulting ltd, 2015. Benzene: 2015 World Market
Outlook and Forecast up to 2019, Birmingham: Merchant Research &
Consulting ltd.
105. N.Palmeri, S. J., 2008. CARBON DIOXIDE ABSORPTION BY MEA. In:
Journal of Thermal Analysis and Calorimetry. Vol.91 ed. Dordrecht:
Akadmiai Kiad, Budapest, p. 8791.
106. Nation Master, ., 2012. Nation Master. [Online]
Available at: http://www.nationmaster.com/country-info/stats/Labor/Salariesand-benefits/Hourly-minimum-wage
107. Platts McGraw hill Financial,, 2014. Platts McGraw hill Financial. [Online]
Available at: http://www.platts.com/newsfeature/2014/petrochemicals/pgpi/benzene
[Accessed 17 11 2015].
108.
Quotent, 2015. Latest Price Naphtha, Mannheim: Quotent.
109. Scott Stevens, K. M., 2013. Technically Recoverable Shale Oil and Shale
Gas Resources: An Assessment of 137 Shale Formations in 41 Countries
Outside the United States, Virginia: U.S. Energy Information Administration.
110. Sean, D., 2008. iHS. [Online]
Available at: http://chemical.ihs.com/nl/Public/2009/0905/0905.html
[Accessed 13 11 2015].
111. Sunsirs, 2015. Sun Sirs. [Online]

[Accessed 17 11 2015].
112. U.S. Department of Energy, 2015. EIA. [Online]
Available at:
http://www.eia.gov/electricity/monthly/epm_table_grapher.cfm?t=epmt_5_3
[Accessed 17 11 2015].
113. World Bank, 2014. Putting a price on carbon with a tax, Washington:
World bank.
114. WORLD HEALTH ORGANIZATION, 2002. IARC MONOGRAPHS ON THE
EVALUATION OF CARCINOGENIC RISKS TO HUMANS. France, IARCPress.
115. Wu, D., 2013. ICIS. [Online]
Available at:
http://www.icis.com/resources/news/2013/01/11/9630910/market-outlookchina-petrochemical-capacity-to-expand-in-2013/
[Accessed 13 11 2015].
116. Baksh, e. (2015). Pressure Swing Adsorption Process For the Production
of Hydrogen. US 6,340,382 B1.
117. Kalthchev, M., .Stacchiola, D., Molero, H., Wu., G., Blumfeld, A. and Tysoe,
W. (1999). On the reaction pathway for the formation of benzene from
acetylene catalyzed by palladium. Catalysis Letter, 60(1999), pp.11-14.
118. Liu, C., Mallinson, R. and Lobban, L. (1998). Nonoxidative Methane
Conversion to Acetylene over Zeolite in a Low Temperature Plasma. Journal of
Catalysis, 179(1), pp.326-334.
119. Farag, H., Ezzat, M., Amer, H. and Nashed, A. (2011). Natural gas
dehydration by desiccant materials. Alexandria Engineering Journal, 50(4),
pp.431-439.
120. Guo, X., Fang, G., Li, G., Ma, H., Fan, H., Yu, L., Ma, C., Wu, X., Deng, D.,
Wei, M., Tan, D., Si, R., Zhang, S., Li, J., Sun, L., Tang, Z., Pan, X. and Bao, X.
(2014). Direct, Nonoxidative Conversion of Methane to Ethylene, Aromatics,
and Hydrogen. Science, 344(6184), pp.616-619.
121.
Process for production of aromatic compound. (2012). US 8097763 B2.
122. Su, L., Liu, L., Zhuang, J., Wang, H., Li, Y., Shen, W., Xu, Y. and Bao, X.
(2003). Creating Mesopores in ZSM-5 Zeolite by Alkali Treatment: A New Way
to Enhance the Catalytic Performance of Methane Dehydroaromatization on
Mo/HZSM-5 Catalysts. Catalysis Letters, 91(3/4), pp.155-167.
123. Ma, D., Shu, Y., Bao, X. and Xu, Y. (2000). Methane Dehydroaromatization under Nonoxidative Conditions over Mo/HZSM-5 Catalysts: EPR
Study of the Mo Species on/in the HZSM-5 Zeolite. Journal of Catalysis,
189(2), pp.314-325.
124.
Solymosi, F. and Szoke, A. (1998). Conversion of ethane into benzene


on Mo2C/ZSM-5 catalyst. Applied Catalysis A: General, 166(1), pp.225-235.
125. Cook, B., Mousko, D., Hoelderich, W. and Zennaro, R. (2009). Conversion
of methane to aromatics over Mo2C/ZSM-5 catalyst in different reactor types.
Applied Catalysis A: General, 365(1), pp.34-41.
126. Solymosi, F., and P. Tolmacsov. 'Conversion Of Ethane Into Benzene On
Re/ZSM-5'. Catalysis Letters 93.1/2 (2004): 7-11. Web.
127. Slocum, D. and Bhasin, M. (1995). Methane and alkane conversion ch
emistry. New York: Plenum Press.
128. Poling, B., Prausnitz, J. and O'Connell, J. (2015). Properties of Gases and
Liquids. 5th ed. McGraw-Hill Education: New York, Chicago, San Francisco,
Athens, London, Madrid, Mexico City, Milan, New Delhi, Singapore, Sydney,
Toronto.
129.
Sinnott, R., Coulson, J. and Richardson, J. (2005). Chemical engineering
design. Oxford: Elsevier Butterworth-Heinemann.
130.
Gicquel, R. (2011). Energy systems. Boca Raton: CRC Press.
131. GmbH, D. (2015). Heat of Fusion of Naphthalene from Dortmund Data

Bank.
[online] Ddbst.com. Available at:
http://www.ddbst.com/en/EED/PCP/HFS_C123.php [Accessed 22 Nov. 2015].
132.
Huvard, G., Felder, R. and Rousseau, R. (2005). Elementary principles of
chemical processes. New York: Wiley.
133. Perry, R., Green, D. and Maloney, J. (1984). Perry's Chemical engineers'
handbook. New York: McGraw-Hill.
134. Neutrium.net, (2012). Conversion of Standard Volumetric Flow Rates of
Gas Neutrium. [online] Available at:
https://neutrium.net/general_engineering/conversion-of-standardvolumetric-flow-rates-of-gas
135.
NFPA 704: Standard System for the Identification of the Hazards of
Materials for Emergency Response. [online] Available at:
http://www.nfpa.org/codes-and-standards/document-informationpages?mode=code&code=704 [Accessed 24 Nov. 2015].
136.
A. Lokhandwala, K. and L. Jacobs, M. (2000). Membranes for fuel gas
conditioning. Hydrocarbon Engineering, (May 2000), pp.81-83.

137.
CAMERON, (2015). Glycol Dehydration Systems. [online] Available at:
https://www.c-a-m.com/products-and-services/separation-processing-andtreatment/gas-processing-and-treatment/glycol-dehydration-systems
[Accessed 9 Nov. 2015].

138.
ChemtechOnline, (2015). Oil & Gas. [online] Available at:
http://www.chemtech-online.com/O&G/Nitin%20Nageshwar_july13.html
139.
EXTERRAN, (2015). Exterran Production Solutions. [online] Available at:
http://www.exterran.com/Content/Docs/Products/Glycol-Dehydration-UnitEnglish-Letter.pdf [Accessed 11 Oct. 2015].

140.
Indexmundi, (2015). Propane - Daily Price - Commodity Prices - Price
Charts, Data, and News - IndexMundi. [online] Available at:

http://www.indexmundi.com/commodities/?commodity=propane
141.
NaturalGas, (2015). Processing Natural Gas NaturalGas.org. [online]
Available at: http://naturalgas.org/naturalgas/processing-ng/#seperateng

142.
NCBI, (2015). National Center for Biotechnology Information. [online]
Available at: https://www.ncbi.nlm.nih.gov/ [Accessed 17 Oct. 2015].

143.
Sulzer, (2015). Sulzer - Coalescer. [online] Available at:
http://www.sulzer.com/en/Products-and-Services/SeparationTechnology/Coalescers [Accessed 3 Nov. 2015].

AII. Record Cards
F. Prasetya
AIII Appendix for Technical Data Used for Design
AIII.VI.1 ENERGY RECOVERY AND UTILITY CALCULATION
To calculate the mass flowrate of water and hot oil as the utility
Q=mCp dT
Where,
Q is the heat duty (kW)
Cp is the constant heat capacity (kJ/kmol K)
*assuming Cp of water is 4.2 kJ/kmol K and for hot oil is 2.3 kJ/kmol K
dT is difference in temperature
*assuming dT for cooling water is 25C, chilled water is 18C, and hot oil is 36C
Example calculation HE-101

412.12 =m (4.2) (25)
m
=5.45 kg/s
To calculate the mass flowrate of steam as utility
Steam table has been used in order to calculate the steam needed. Based on the
table that has been showed in the report, the steam has been divided into 3
parts which are low, medium, and high pressure steam.
ms =
q
he
Where
ms = mass of steam (kg/s)
q = calculated heat duty (kW)
he = evaporation energy of the steam (kJ/kg)
Example calculation- HE-102

699.00
ms
=2164.00
=0.33 kg/s
Calculation of total water needed for steam generation system

Total steam needed is 1.7 kg/s
Assumption made in the calculation
1. Blowdown is 7%
2. Efficiency of the boiler is 80%
3. Type of boiler is not assumed
F. Prasetya
Since the total steam needed is 1.7 kg/s and the blowdown rate is 7% of the
feed. Thus the total water needed is
F=S+0.07F
F refers to water needed
S refers to steam needed
F
= S + 0.07 F
0.93 F = S
1.7
F
= 0.93
F
=1.83 kg/s
Calculation of boiler energy

Boiler Energy = Steam Energy Flow + Blowdown Energy Flow Feedwater Energy Flow
Steam energy flow = Mass of steam enthalpy of steam

= 1.7 2801
= 4761.70 kW
Blowdown energy flow
= Mass of blowdown enthalpy of blowdown

= 0.13 1087
= 139.24 kW
Feedwater energy flow
= Mass of feedwater enthalpy of feedwater

= 1.83 454.22
= 831.22 kW
Boiler energy = 4761.60 + 139.24 831.22

= 4069.72 kW
Fuel oil needed
= Boiler energy/ heating value of butane

= 4069.72/45227.00
= 0.09 kg/s
Calculation of chilled water system

Total water needed for chilled water system
= 52.71 kg/s 189756 kg/hr
Q= c p q dT
Q=500 q dT
Where,
Cp refers to specific heat, 1 (Btu/lbm F)
refers to 8.33 (lbm/US gal) for water
dT refers to temperature difference (F)
q refers to water flowrate (US Gal/min)
F. Prasetya
Q=500 (835.47) (32)

Q= 13367520 Btu/hr
A ton is the amount of heat removed by an air conditioning system that would
melt 1 ton of water is 12000 BTU/hr. Hence, the ton of refrigeration that needed
to cool down the water is
Cooling load
= 13367520/12000 BTU
= 1113.96 ton of refrigeration
Latent heat of evaporation of ammonia

Amount of refrigeration needed
= 589.3 BTU/lb
= 13367520/589.3 BTU
= 22683.73 lb/hr 10.29 ton/hr
Calculation of makeup water needed for cooling water system

Total water needed = 350.34 kg/s
Density of water
= 1000 kg/m3
Evaporation loss
m3
= 0.00153 dT recirculation rate ( hr )

= 0.00153 (52-25)
350.34 3600
1000
= 52.10 m3/hr 14.47 kg/s

Assumption
1. Cycle of concentration is 1.5

2. Drift loss is 0.1% of the total makeup water
Blowdown loss
=
=
evaporation rate
cycle-1
14.47
1.5-1
= 28.95 kg/s
Total make up water = 14.47 + 28.95 + 0.1 (14.47+28.95)
= 43.47 kg/s
Calculation of energy release by turbine in steam generation system

Inlet
Steam at medium pressure (20 bar and 212.4 C)
Outlet
Steam at low pressure (3 bar and 133.50 C)
S inlet = 6.340 kJ/kg K
Assume isentropic thus S outlet = S inlet
However, S outlet = 6.993 kJ/kg K
Thus S outlet is a mixture
F. Prasetya
x (1.672)+(1-x)(6.993)=6.340
x=0.12
Thus enthalpy calculated is
H=0.12 (561)+(1-0.12)(2725)=2465.32 kJ/kg
H inlet = 2799 kJ/kg
Assume that turbine efficiency is 80%
2799-h actual
2799-2465.32
H actual = 2532.06 kJ/kg
0.8=
Energy release by the turbine
= m (h1-h2)
= 0.94 (2799-2532.06)
= 250.49 kW
J.K.C. Chan
AIII.VII.1 ENVIRONMENTAL PROTECTION
VII.3.2.2 Leopold Matrix Table
J.K.C. Chan
VII.4.3.1 Calculations
1) Mass Balance and Sizing of BR-101 & BR-102
Mass Balance
Table VII.5.3.1: Mass Balance Components of Stream F2 & F3 in BR-101 & BR102
Components
F1
(kg/h)
F1
m3/h)
F2
(kg/h)
F2
(m3/h)
F3
(kg/h)
F3
(m3/h)
CO2
0.0007
0.0004
0.0000
0.0004
0.1200
0.0631
N2
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
CH4
0.0000
0.0000
0.0000
0.0000
C2H6
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
C3H8
0.0313
0.0166
0.0300
0.0166
0.0000
0.0003
0.0031
0.0000
0.0076
0.0031
9.8109
E-07
0.0100
0.0000
0.0384
0.0000
0
0.0584
5
46.1200
9.8110 E
-07
0.0461
46.2800
6.1357 E
-05
1.9622 E
-08
0.0463
0.0000
0.1400
0.0000
0.0662
46.5500
0.1098
C4H10
C5H12
H20
0.0006
38.4056
Biomass
0.0000
Total
38.4459
0.0000
0.0800
46.1559
Step 1) VOC decomposition in stream F2:

Example of calculation for C2H6, C3H8, C4H10 & C5H12 removal in stream F2:
Mass flowrate of C2H6 removal in F2 = 0.03130.98 =0.0307 kg/h
Thus, the resulting mass flowrate of C2H6 in F3 is 6x10-4 kg/h, the complete
flowrate for all components is calculated and is summarized in Table VII.4.2.3
Step 2) Production of CO2 and H2O due to the Aerobic Decomposition
2CnH2n+2 (n=1-5) + (3n+1) O2
, where (n=1-5)
Pseudomonas Putida
2nCO2 + (2n+2) H2O
(Equation VII.4.2.1)
Example of calculation for CO2 contribution by C2H6, C3H8, C4H10 & C5H12 in
stream F2:
Mass Flowrate of CO2 contributed by C4H10 = 30.980.0076
=0.0223 kg/h
Thus, the resulting mass flowrate of CO2 contributed by C3H8 in F3 is 0.0223 kg/h,
the complete flowrate for all components is calculated and is summarized in
table 9.4.2.3
Example of calculation for H2O contribution by C2H6, C3H8, C4H10 & C5H12 in
stream F2:
Mass Flowrate of H2O contributed by C4H10 = 40.980.0076
J.K.C. Chan
=0.0298 kg/h
Thus, the resulting mass flowrate of H2O contributed by C3H8 in F3 is 0.0298
kg/h, the complete flowrate for all components is calculated and is
summarized in table 9.4.2.3
Step 3) Production of Biomass Using Monods Equation:
Given that maximum growth rate constant, max =0.0047 h-1; half saturation
constant Ks= 10mg/l(Kermanshahi pour, 2006); ; concentration of biomass, X
In order to find out the growth rate constant at t=12 hours, S=Concentration of
Limiting Food (VOC in this case, mg/l)
Thus from stream F2 in Table VII.4.2.2, S = 0.039555/0.019703
= 2.0076 kg/m3
= 2007.60 mg/l
Find instantaneous growth rate constant,
(0.0047)(2007.60)
(10)+(2007.60)
0.0047 h-1
This proves that the microbial growth condition is under excess of food, thus
equation (VII.4.3.2) remains.
Integrating Equation (VII.4.3.2) to get a linearized form:
ln = +
At t=0, X=1208.46 mg/l, find C,
ln(1208.46) =
Find x, when t=12 hours (HRT):
X= 1208.46
= 1208.46 (0.0047)(12)
=1278.58. mg/l
Therefore,
mass flowrate of biomass generated in F3 =1278.580.1098/1000
J.K.C. Chan
=
0.1404 kg/h
Sizing of Bioreactors
Given that HRT =12 hours, volumetric flowrate of F1= 0.05846 m3/h
Therefore, actual volume of bioreactor
= 120.05846
= 0.7016 m3
2) Mass Balance for CR-101:

Table VII.5.3.2: Mass Balance Components of Stream F4 & F9 in CR-101
Components F4 (kg/h)
CO2
N2
CH4
C2H6
C3H8
C4H10
C5H12
H20
Biomass
Total
0.1200
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
46.2800
0.1400
46.5500
F4 (m3/h)
F9(kg/h)
0.0631
0.0000
0.0000
0.0000
0.0003
6.1357 E-05
1.9622 E-08
0.0463
0.0000
0.1098
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
9.2600
0.0840
9.3409
F9 (m3/h)
0.0319
0.0000
0.0000
0.0000
0.0002
2.4651 E-05
3.1345 E-11
3.7024 E-05
0.0000
0.0321
Step 1) Biomass recycled and water retention due to biomass in stream F9:
Mass flowrate of biomass recycled in F9 = 0.14 0.6
=0.084 kg/
Mass flowrate of water retention in recycled biomass at F9 = 46.28 0.2
= 9.26 kg/h
Step 2) Biomass residue and main water composition in stream F10:
Mass flowrate of biomass recycled in F9
= 0.14-0.084 kg/h
= 0.056 kg/h
Mass flowrate of water retention in recycled biomass at F10
= 46.28 0.8
=37.024 kg/h
3) Mass Balance for MR-102:

J.K.C. Chan
Table VII.5.3.3: Mass Balance Components of Stream F9 & F10 in MR-102
Components F10 (kg/h)
CO2
N2
CH4
C2H6
C3H8
C4H10
C5H12
H20
Biomass
Total
F10 (m3/h)
0.1200
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
37.0200
0.0700
37.2200
F11(kg/h) F11(m3/h)
0.0631
0.0000
0.0000
0.0000
0.0003
6.1357 E-05
1.9622 E-08
0.0370
0.10000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
0.0000
37.0200
0.0000
37.0300
0.0006
0.0000
0.0000
0.0000
0.0003
6.1357 E-05
1.9622 E-08
0.0370
0.0400
Step 1) Biomass residual in F11:

Mass flowrate of biomass recycled in F11
= 0.07 (1-0.99)
=710-4 kg/h
VII.6.1 Local Ambient Air Quality Standards

Table VII.6.1.1: Local Ambient Air Quality Standards (GB 3095-2012)
No.
Parameter
1
2
3
4
5
6
7
8
9
10
SO2
NO2
CO
O3
PM10
PM2.5
TSP
NOx
Pb
BaP (Benzopy
rene)
Average Allowable
Emission Con
Duration Concentration centration
1 hour
1 hour
1 hour
1 hour
24 hour
24 hour
24 hour
1 hour
1 year
150 g/m3
200 g/m3
10 mg/m3
160 g/m3
50 g/m3
35 g/m3
120 g/m3
250 g/m3
0.5 g/m3
Trace
Trace
Reasonable
Trace
Trace
Trace
Trace
Trace
Trace
1 year
0.001 g/m3
Negligible
Description
Below Limit
Below Limit
Satisfies
Below Limit
Below Limit
Below Limit
Below Limit
Below Limit
Below Limit
Below Limit
J.K.C. Chan
VII.6.2 Environmental Quality for Surface Water Standards
Table VII.6.2.1: Environmental Quality for Surface Water Standards (GB 38382002)
No.
Parameter
Allowable Co
ncentration
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Temperature
pH
DO
CODMn
COD
BOD5
NH4+
T P
T N
Cu
Zn
FSe
As
Hg
Cd
Pb
Cr5+
CNPhenol
Oils
Surfactants
S2Pathogenic
Count
1 or 2C
6-9
7.50 mg/l
2.00 mg/l
15.00 mg/l
3.00 mg/l
0.15 mg/l
0.02 mg/l
0.20 mg/l
0.01 mg/l
0.05 mg/l
1.00 mg/l
0.01 mg/l
0.05 mg/l
0.00005 mg/l
0.001 mg/l
0.01 mg/l
0.01 mg/l
0.005 mg/l
0.002 mg/l
0.05 mg/l
0.2 mg/l
0.05 mg/l
Emission Conc
entration/ Diff
erence
0
6
Small deviation
Small deviation
Small deviation
Reasonable
Trace
Trace
Trace
Trace
Trace
Trace
Trace
Trace
Negligible
Negligible
Negligible
Negligible
Negligible
Negligible
Trace
Trace
Trace
Trace
Description
Below Limit
Satisfies
Below Limit
Below Limit
Below Limit
Satisfies
Below Limit
Below Limit
Below Limit
Below Limit
Below Limit
Below Limit
Below Limit
Below Limit
Below Limit
Below Limit
Below Limit
Below Limit
Below Limit
Below Limit
Below Limit
Below Limit
Below Limit
Below Limit
200 mg/l
A.B. Verasingham
AIII.X.1 ECONOMIC EVALUATION
Sizing and Costing for Each Equipment
General Safety Margins (Sizing)
-
20% more flow (during initial startup).

Vessels should be kept at 50% of the total volume.
Holdup Time of 5 to 10 minutes is sufficient for vessels with modern control systems.
Main Equipment Sample:

Heat Exchangers
Item No.
Units
Lower
Upper
Actual (S)
HE-107
m
10.00
1,000.00
968.58
The heat exchangers were sized using the equation Q = UATm
For HE-107; tube inlet = 190C
180C
U = 50 W/m2 C
a
24,000.00
tube outlet = 163.9C
Q = 2,215,960 W
m2
Tm =
190180
163.938
190180
163.938
Ce, USD
46.00 1.20 200,246.69 1,025,263.05
shell inlet = 38C
= 45.76
C, USD
A =
Tm
shell
outlet
2,215,960
50 x 45.76
= 968.58
*The following costing substitution was carried out for every equipment listed in the Table X.1.1.2 using the
factors in Table X.1.1.1, Equation X.1.1.1 and Equation X.1.1.2 from Section X.
Ce = a+bSn
69
Ce = 24,000.00+46.00(968.58)1.2 = USD 200,246.
C = =
= 1 ,, fPft[(1+fp)fm+(fer+fel+fi+fc+fs+fl)]
C = 200,246.691(1)(1.6)[(1+0.8)1.0+(0.30+0.30+0.20+0.30+0.20+0.10)] = USD 1,025,263.05
61| A p p e n d i x
A.B. Verasingham
*all the heat exchangers were sized using the same method and all the following equipment were costed similarly.
Crystallizer
Item No.
Units
Lower
Upper Actual (S)
a
b
n
Ce
C
CR-101
m
7.00
280.00
3.2
8,400.00
11,300.00 0.80 8,400.00 26,880.00
The crystallizer was sized by first increasing the flow rate by 50%, a holdup time of 8 hours was taken. By multiplying the
flowrate by the holdup time, the volume was determined. After which, the length and width of the rectangular shaped
crystallizer was calculated using the V = length x height x width.
Flow rate = 0.692 m3/hr
Excess Flow Rate = 1.50 x 0.692 m3/hr = 0.830 m3/hr
Volume = 0.830m3/hr x 8 hr = 6.64 m3
*the length and height was determined manually to achieve a ratio of 1:2
*Costing was done as shown for HE-107

Furnace
Item No.
Units
Lower
Upper Actual (S)
a
b
n
Ce
C
F-101
MW
0.20
60.00
6.11
37,000.00 95,000.00 0.80 441,415.42 2,966,311.62
The furnace was sized using the duty calculated from Section V Heat Integration.
Reactor
Item No.
Units
Lower
Upper
Actual (S)
Ce
RX-101
m
0.50
100.00
63.63
53,000.00 28,000.00 0.80 829,403.65 6,514,136.29
The reactor was sized using the calculations performed in Section VI.3 RX-101
62| A p p e n d i x
A.B. Verasingham
Distillation Column
Item No.
Units
Lower
Upper
Actual (S)
a
b
n
Ce
C
DC-101
shell mass, kg
160.00
250,000.00
617.42
10,000.00 29.00 0.85 16,829.53 53,854.51
The shell mass was calculated using the formula;
tw =
where;

(2 )(1.2 )
Dc = vessel diameter,m
Shell Mass = DcLctw
Lc = vessel length,m tw = wall thickness,m =metal density
The values were extracted from Section VI.1 DC-101

Shell Mass = x 0.95 x 6.22 x 0.01 x 7850 = 617.42
Flash
Item No.
Units
Lower
Upper
Actual (S)
Ce
FV-101
shell mass, kg
160.00
250,000.00
408.22
10,000.00 29.00 0.85 14,804.64 55,369.36
The sizing method used is similar to that of the crystallizer except since flash vessels have a spherocylinder shape the length
4
and height were determined using V = r2 ( 3 + ) and the holdup time was 10 minutes. Except for vertical vessels the length
to diameter ratio should be less than 5.

DC Trays
Item No.
Units
Lower
Upper Actual (S)
DC-101
diameter, m
0.50
5.00
0.95
The values were extracted from Section VI.1 DC-101.
a
110.00
b
n
380.00 1.80
Ce
456.49
C
20,450.59
63| A p p e n d i x
A.B. Verasingham
Storage Tanks
Item No.
Units
Lower
Upper
Actual (S)
Ce
WS-101
m
10.00
4,000.00
1,126.48
5,000.00 1,400.00 0.70 196,573.46 629,035.07
The sizing method used is similar to that of the crystallizer except since flash vessels have a cylinder shape the length and
height were determined using V = ( 4 2 ). Except for vertical vessels the length to diameter ratio should be less than 5.
Expanders and Condensers
Item No.
Units
Lower
Upper
Actual (S)
a
b
n
Ce
C
EX-101
kW
75.00
30,000.00
694.63
580,000.00 20,000.00 0.60 1,594,103.12 7,651,694.96
The expanders and condensers was sized using the duty calculated from Section IV.4 Energy Balance.
Single Stage Centrifugal Pumps
Item No.
Units
Lower
Upper Actual (S)
a
P-101
flow, L/s
0.20
126.00
0.20
6,900.00
The pump was sized using the flow rate calculated from Section IV.3 Mass Balance.
b
n
206.00 0.90
Ce
6,948.39
C
20,150.34
Ce

Reflux Drum
Item No.
Units
Lower
Upper
Actual (S)
RD-102
shell mass, kg
160.00 250,000.00
5.35
10,000.00 29.00 0.85 10,120.64 32,386.05
The sizing method used is similar to that of the crystallizer except since reflux drums have a spherocylinder shape the length
4
and height were determined using V = r2 ( 3 + ) and the holdup time was taken at 8 minutes. Except for horizontal vessels
64| A p p e n d i x
A.B. Verasingham
the length to diameter ratio should be more than 5.
List of Equations for Table X.7.1
Profit before Depreciation Interest and Tax = Sales Revenue Operating Cost
Depreciation =
20
Profit before Interest and Tax = Profit before Depreciation Interest and Tax Depreciation Cost
Interest =0.04 (Profit before Interest and Tax)
Profit before Tax = Profit before Interest and Tax Interest Rate
Taxable Income = Gross Profit Tax Allowance
Tax Allowance = 0.50(Catalyst Cost + Membrane for R&D)
Tax Implemented (Corporate Tax) = Taxable Income x 0.15
Final Profit After Tax = Profit before Tax - Tax Implemented
ROI =
( )

( )

65| A p p e n d i x
A.B. Verasingham
Table VII.X.1: Sizing Methodology for Selected Equipment.
Item
No.
FV-101
Density (k
mol/m3)
Flow rate (
kmol/hr)
Flow rate (
m3/hr)
Excess flow rat

e (m3/hr)
Holdup tim
e (hr)
Volume (
m3)
47.133
996.3
21.20614614
25.44737537
0.17
4.24122922
79.717
6969.15
87.42363611
104.9083633
0.17
17.4847272
47.133
994.17
21.09381902
25.31258283
0.17
4.21876380
79.717
6839.842
85.80154798
102.9618576
0.17
17.1603096
47.133
992.56
21.05870621
25.27044746
0.25
6.31761186
WS-10
1
1000
78228
78.228
93.8736
12.00
1126.4832
WS-10
2
1000
78228
78.228
93.8736
12.00
1010
1.73
0.001712871
0.002055446
20.04066
104.4
2.604704635
20.04066
104.4
11.9139
FV-102
DH-101
DH-102
PSA
MR-101
SO-103
SO-105
SO-105
SO-106
SO-107
SU-101
RD-101
RD-102
RD-103
RD-104
RD-105
CR-101
Shape
Radius
(m)
Shell Mas
s, kg
Diameter
(m)
Length
(m)
Capsule
0.61
408.2231
1.22
6.44197
Capsule
0.98
538.0672
1.96
10.2819
Capsule
0.61
406.1511
1.22
6.40354
Capsule
0.99
511.5499
1.98
9.82496
Cylinder
0.9
180.6059
1.8
4.96468
2252.9664
Cylinder
12
19.9180
1126.4832
2252.9664
Cylinder
12
19.9180
24.00
0.0493306
0.09866138
6
Cylinder
0.15
0.3
1.39559
3.125645563
12.00
37.507746
75.0154935
Cylinder
1.6
3.2
9.32620
2.604704635
3.125645563
12.00
37.507746
75.0154935
Cylinder
1.6
3.2
9.32620
7.11
0.59678191
0.716138292
12.00
8.5936595
Cylinder
0.9
1.8
6.75331
11.248
7.782566
0.69190665
0.83028798
12.00
9.9634557
Cylinder
6.34211
1010
62.42
0.06350198
0.076202376
6.00
0.4572142
Cylinder
0.3
0.6
3.23371
24.31
29.172
0.08
2.431
4.862
Capsule
0.44
50.9
0.88
3.40977
4.612875
23.22
5.076892625
6.092271149
0.13
0.81230282
1.62460564
Capsule
0.28
5.35
0.56
2.92424
78.69214
9.56
9.567386085
Capsule
0.35
5.49
0.7
3.51047
20.04066
104.4
32.51930927
Capsule
0.5
11.67
5.95725
11.9139
7.11
0.820072669
Capsule
0.15
0.984
0.3
1.65602
11.248
7.782566
0.69190665
Cuboid
3.32115
*The values in green are what were substituted in Ce =
150% Volu
me (m3)
8.48245845
6
34.9694544
5
8.43752760
9
34.3206191
9
12.6352237
3
17.1873190
1
19.9269115
2
0.91442851
5
3.06156354
7
10.4061789
39.02317113
0.13
5.20308948
7
0.26242325
0.984087203
0.13
0.13121162
4
13.2846076
0.83028798
8.00
6.64230384
8
.
a+bSn and C = =
f
f
[(1+f
)f
+(f
+f
+f
+f
+f
+f
)]
p m
er
el
i
c
s
l
= 1 ,, P t
11.4808633
0.13
1.53078177
L/D R
atio
5.2803
07
5.2458
78
5.2488
07
4.9621
01
2.7581
58
5.8747
43
5.2218
74
5.0149
63
5.9572
53
5.5200
80
1.6605
75
66| A p p e n d i x
A.B. Verasingham
Table VII.X.2: S values calculated for each equipment using the Factorial Method.
Item No.
Units
Actual (S)
HE-107
m2
968.58
HE-112
1,000.00
347.67
HE-114
28.77
HE-101
m2
58.59
Heat Exchangers
m
HE-113
HE-106
HE-108
HE-109
HE-110
HE-111
HE-116
HE-117
HE-102
HE-103
HE-104
HE-105
HE-115
CD-101
CD-102
CD-103
CD-104
CD-105
RE-101
RE-102
RE-103
RE-104
RE-105
Crystaliser
CR-101
Furnace
F-101
F-102
Reactor
m
m2
m2
m2
m2
m2
m2
m2
m2
m2
m2
m2
m2
m2
m2
m2
m2
m2
m2
m2
m2
m2
m
RX-101
RX-102
Pressure Vessels
DC-101
DC-102
DC-103
DC-104
FV-101
FV-102
PSA
TSA
MR-101
RD-101
RD-102
RD-103
RD-104
RD-105
SC-101
ST-101
Trays/Packing
DC-101
DC-102
DC-103
10.00
280.75
382.90
315.74
461.00
10.00
175.00
28.10
10.00
14.00
10.00
10.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
MW
MW
6.11
0.76
m3
63.63
63.63
m
shell
shell
shell
shell
shell
shell
shell
shell
shell
shell
shell
shell
shell
shell
shell
shell
mass,
mass,
mass,
mass,
mass,
mass,
mass,
mass,
mass,
mass,
mass,
mass,
mass,
mass,
mass,
mass,
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
kg
617.42
1,043.09
4,069.99
357.39
408.22
538.07
511.55
406.15
180.61
50.90
5.35
5.49
11.67
0.98
151.42
151.42
diameter, m
diameter, m
diameter, m
0.95
0.76
1.02
DC-104
m3
0.84
SC-101
40.00
40.00
ST-101
Storage Tanks
m
m
A.B. Verasingham
WS-101
m3
1,126.48
WS-102
1,126.48
0.05
37.51
37.51
8.59
9.96
0.46
kW
kW
kW
kW
694.63
1,450.74
2,350.50
2,447.28
SO-103
SO-105
SO-105
SO-106
SO-107
SU-101
Expander and Compressors
EX-101
C-101
C-102
C-103
Pumps
P-101
P-102
P-103
P-104
P-105
P-106
P-107
P-108
m
m
m
m
m
m
flow,
flow,
flow,
flow,
flow,
flow,
flow,
flow,
L/s
L/s
L/s
L/s
L/s
L/s
L/s
L/s
0.20
0.20
0.20
0.20
0.20
0.20
0.20
0.20
A.B. Verasingham
Table VII.X.3: Cumulative Cash Flow, Net Discounted Cumulative Cash Flow with Respect to Number of Years.
Year
0.00
1.00
2.00
3.00
4.00
5.00
6.00
7.00
8.00
9.00
10.00
11.00
12.00
13.00
14.00
15.00
16.00
17.00
18.00
19.00
20.00
21.00
22.00
23.00
24.00
25.00
26.00
27.00
28.00
29.00
30.00
Investment
0.00
-82,320,825.81
-4,945,592.77
-3,709,194.58
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
Operating Cost
0.00
0.00
0.00
-37,676,081.20
-56,739,611.84
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
-62,532,214.69
Sales Revenue
0.00
0.00
0.00
38,391,518.76
63,985,864.60
115,174,556.28
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
127,971,729.20
The taxing starts from the 6th year onwards.
Taxable income
-21,236,782.65
-14,705,967.45
30,690,121.37
43,487,294.29
43,487,294.29
43,487,294.29
43,487,294.29
43,487,294.29
43,487,294.29
43,487,294.29
43,487,294.29
43,487,294.29
43,487,294.29
65,439,514.51
65,439,514.51
65,439,514.51
65,439,514.51
65,439,514.51
65,439,514.51
65,439,514.51
65,439,514.51
65,439,514.51
65,439,514.51
65,439,514.51
65,439,514.51
65,439,514.51
65,439,514.51
65,439,514.51
Taxation rate
0.00
0.00
0.00
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
0.15
Tax paid
0.00
0.00
0.00
0.00
0.00
0.00
4,497,938.21
6,417,514.14
6,417,514.14
6,417,514.14
6,417,514.14
6,417,514.14
6,417,514.14
6,417,514.14
6,417,514.14
6,417,514.14
6,417,514.14
9,710,347.18
9,710,347.18
9,710,347.18
9,710,347.18
9,710,347.18
9,710,347.18
9,710,347.18
9,710,347.18
9,710,347.18
9,710,347.18
9,710,347.18
9,710,347.18
9,710,347.18
9,710,347.18
Net Cash Flow

0.00
-82,320,825.81
-4,945,592.77
-2,993,757.02
7,246,252.76
52,642,341.59
60,941,576.30
59,022,000.36
59,022,000.36
59,022,000.36
59,022,000.36
59,022,000.36
59,022,000.36
59,022,000.36
59,022,000.36
59,022,000.36
59,022,000.36
55,729,167.33
55,729,167.33
55,729,167.33
55,729,167.33
55,729,167.33
55,729,167.33
55,729,167.33
55,729,167.33
55,729,167.33
55,729,167.33
55,729,167.33
55,729,167.33
55,729,167.33
55,729,167.33
Cummulative Cash
Flow
0.00
-82,320,825.81
-87,266,418.58
-90,260,175.60
-83,013,922.84
-30,371,581.25
30,569,995.05
89,591,995.41
148,613,995.77
207,635,996.13
266,657,996.50
325,679,996.86
384,701,997.22
443,723,997.58
502,745,997.94
561,767,998.31
620,789,998.67
676,519,166.00
732,248,333.33
787,977,500.66
843,706,667.98
899,435,835.31
955,165,002.64
1,010,894,169.97
1,066,623,337.30
1,122,352,504.63
1,178,081,671.96
1,233,810,839.29
1,289,540,006.62
1,345,269,173.95
1,400,998,341.28
DCFRR =
Interest (%) =
Net Discounted Cash Flow

0.00
-63,079,482.27
-51,239,390.64
-40,609,849.43
-28,619,664.86
-8,023,417.88
6,188,220.48
13,896,902.85
17,663,913.32
18,910,728.57
18,609,668.16
17,416,204.04
15,763,957.73
13,932,599.05
12,096,124.44
10,356,977.23
8,769,990.82
7,323,403.01
6,073,927.77
5,008,451.24
4,109,221.16
3,356,731.64
2,731,512.80
2,215,179.54
1,790,988.19
1,444,073.58
1,161,485.64
932,106.27
746,500.44
596,736.83
476,200.31
Net Discounted Cummulative Cash Flow

0.00
-63,079,482.27
-114,318,872.91
-154,928,722.34
-183,548,387.21
-191,571,805.09
-185,383,584.61
-171,486,681.76
-153,822,768.44
-134,912,039.87
-116,302,371.71
-98,886,167.67
-83,122,209.95
-69,189,610.90
-57,093,486.45
-46,736,509.23
-37,966,518.40
-30,643,115.40
-24,569,187.63
-19,560,736.39
-15,451,515.23
-12,094,783.59
-9,363,270.79
-7,148,091.26
-5,357,103.06
-3,913,029.48
-2,751,543.84
-1,819,437.58
-1,072,937.14
-476,200.31
0.00
0.00
30.50
A.B. Verasingham, F. Prasetya, Y.S.E. Soh
AIV Appendix for Detailed Design Calculation

AIV. VI.I: Formula and Graph for DC
List of Formulas for DC-101, DC-102 and DC-103.
DC Formula 1 = + (+)
T = C, P = mmHg
DC Formula 3
DC Formula 4
, = , ,
x = 1
Bubble point:
DC Formula 5
DC Formula 2
x =
y
K
y = 1
DC Formula 6 Dew Point:
y = K x
DC Formula 7
Minimum Number of Stages at Total Reflux
Fenske Equation
Nm
xLK xHK
log

xHK d xLK b
where:
LK , av
HK , av
log
LK , a v is the average relative volatility of the light key with respect to

the heavy key,
concentrations.
and
xLK
and
xHK
are
the
light
and
heavy
key
Note that, by definition, H K, a v = 1.0, since the heavy key is taken here
as the reference component.
The relative volatility is taken as the
geometric mean of the values at the column top and bottom
temperatures:
DC Formula 8
xLK, D xLK, F
ln
xHK, D xHK, F
( Nm) rect
LK , av( rect )
ln
HK , av( rect )
DC Formula 9
xLK, F xHK, B
ln
xHK, F xLK, B
( Nm) strpt
LK , av( strip)
ln
HK , av( strip)
DC Formula 10
i ,av xi ,d
Rm 1
i , av
where:
i , a v = relative volatility of component i with respect to some reference

component, usually the heavy key,
R m = the minimum reflux ratio,

x i , d = concentration of component i in the tops at minimum reflux.
DC Formula 11
i , av zi , f
i , av
1 q
where z i , f = the concentration of component i in the feed, and q

depends on the saturation condition of the feed: q = heat to vaporise 1
mol of feed/molar latent heat of feed.
Thus 1 q is the fraction of
feed that is vapour.
The value of must lie between the values of the relative volatility of
the light and heavy keys, and is found by trial and error.
DC Formula 12
2
m B ZHK ( xLK ) bottoms

p D ZLK feed ( xHK ) distillate
DC Formula 13
mean, av
LK , av HK , av
DC Formula 14
Wi
0.206
Fi
D
1 i ,av
W HK HK ,av
where;
Di = F i - Bi
Nm
DC Formula 15 log = ( ); T in K
DC Formula 16 =
Column Pressure Determination

DC Formula 17 V = D(1+R)
DC Formula 18 L = RD
DC Formula 19 V = V-F
DC Formula 20 L = L
Column Diameter
DC Formula 21 = ()
Corrected Surface Tension

Using, Figure 11.27 K1 was obtained.
0.2
)
0.02
DC Formula 22 1() = (
1
Vapour flooding velocity, Uf

(
DC Formula 23 = 1
Vapour Velocity based on net cross-sectional area, Un

DC Formula 24 =
Maximum volumetric flow rate, vg
DC Formula 25 vg = V kmol/h MW kg/kmol
1
3600
3 /
hs-1
Net Area
DC Formula 26 Net Area =
Cross-sectional Area, Ac
DC Formula 27 Cross-sectional area, Ac =
Column Diameter, DC
DC Formula 28 =
(1 %)
( 4)
Maximum Liquid Flow Rate, vL

DC Formula 29 vL = V kmol/h MW kg/kmol
Downcomer Area, Ad
DC Formula 30
Net Area, An
DC Formula 31
Active Area, Aa
DC Formula 32
Hole Area, Ah
DC Formula 33
Using Figure 11.31,
DC Formula 34
DC Formula 35
3 /
1
3600
hs-1
3 /
Ad = Ac B, B= % of column area
A n = Ac Ad
Aa = Ac 2Ad
Ah = Y Aa, Y= % of active area
=
=
Maximum Liquid Rate, Lmax

DC Formula 36 Lmax = L kmol/h MW kg/kmol
DC Formula 37 Lmax = L kmol/h MW kg/kmol
1
3600
1
3600
h/s x
h/s
Minimum Liquid Rate, Lmin

DC Formula 38 Lmin = % of turndown rate Lmax
2/3
)

2/3
DC Formula 39 Maximum, how(max) = 750 (

DC Formula 40 Minimum, how(min) = 750 (
At minimum rate;
DC Formula 41 hw + how
Minimum Vapour Design Velocity, Uh, min
25.4
DC Formula 42 Uh, min = 2 0.9 ( ( )0.5 )
*dh= hole diameter
Actual Minimum Vapour Rate, Uh (a)

DC Formula 43 () =
Using Figure 11.34 Co,
DC Formula 44 = ,
= 1
Maximum Vapour Velocity, Uh

DC Formula 45 =
Dry Plate Pressure Drop, hd
DC Formula 46 = 51 ( )
Residual Head, hr
DC Formula 47 =
12.5 103
Total Plate Drop, ht

DC Formula 48 = + ( + ) +
Total Plate Pressure Drop,
DC Formula 49 = 9.81 103
DC Formula 50 Total Pressure Drop =
Downcomer Pressure loss, hap
DC Formula 51 = (5 10 )
Area under apron, Aap
DC Formula 52 Aap= lw x hap
Head loss in the downcomer, hdc
DC Formula 53 = 166 (
Backup in Downcomer, hb
DC Formula 54 = ( + ) + +
1
(
2
and must be less than
+ )
Downcomer Residence Time

DC Formula 55 =
Entrainment Check
DC Formula 56 =
DC Formula 57
From Figure 11.29, = constant using Flv, bottom

Trial Layout
*Use cartridge-type construction. Allow 50mm unperforated strip round
plate edge; 50mm wide calming zones.
From Figure 11.32,
DC Formula 58 =
DC Formula 59
DC Formula 60 Angle substended by the edge of the plate = 180 - c

DC Formula 61 Mean length, unperforated edge strips =
Angle substended by the edge of the plate

(
)
1000
180
DC Formula 62 Area of unperforated edge strips = 50 103 mean length,
unperforated
edge strips
DC Formula 63 Mean length of the calming zone approx = weir length
+ width of unperforated strip
DC Formula 64 Area of calming zones = 2 Mean length of the calming
zone approx
1000
Total area of perforation, Ap

DC Formula 65 = Area of unperforated edge strips Area of calming zones
DC Formula 66
DC Formula 67
=
=2
DC Formula 68 Area of One Hole =
5
1000
DC Formula 69 Number of holes =
DC Formula 70 Column Area = =
2
4
DC Formula 71 Tower Height = (tray spacing number of trays) + (tray

thickness
Number of trays) + (dome height 2)
DC Formula 72 Tower Volume = Column Area Tower Height
DC Graph 1: Flooding Velocity, Sieve Plates
DC Graph 2: Weep Point Correlations
DC Graph 3:
Relation between Downcomer Area and Weir Length
DC Graph 4: Relation Between Angle Subtended by Chord, Chord Height and Chord Length
DC Graph 5: Relation Between Hole and Pitch
DC Graph 6: Dishcharge Coefficient, Sieve Plates
DC Graph 7: Downcomer Back Up
DC graph 10: Erbar-Maddox graph

DC Graph 8: Selection of Liquid-Flow Arrangement
DC Graph 9: Entrainment Correlation for sieve plate
A.B. Verasingham
AIV. VI.1: DC-101 Calculation

Section VI.1 DC-101 Detailed Calculations (refer to AIV.VI.I for the DC
formula and graph)
*Please refer to the manual mass balance under Section IV.2.32.
Table VI.1.4: Manual Mass Balance for DC-101.
i
1 (kmol/h)
zi,1
2 (kmol/h)
C3H8
46.73
0.6439
46.263
C4H10
19.3027
0.2724
0.4673
C5H12
6.07
0.0836
0
Sum
72.57
1
46.73
yi,2
0.99
0.01
0
1
3 (kmol/h)
0.4673
19.3027
6.07
25.84
xi,3
0.01808
0.74700
0.23490
1
Assumptions
All HNK is at the bottom.
Propane purity = 0.99
Propane Recovery = 0.99
*The light key (LK) and heavy key (HK) was 0.018 and 0.01 respectively.
Table VI.1.5: Antoine Equation Constants (Yaws Handbook).
LK
HK
HNK
Chemical
Propane
Butane
Pentane
A
7.01887
7.00961
7.00877
B
889.864
1022.48
1134.15
C
257.084
248.145
238.678
Tmin, C
-187.69
-138.29
-129.73
Tmax, C
96.67
152.03
196.5
By using the antoine equation and the constants in Table VI.1.4 the saturated
pressure was determine. The k-values were then determined by using DC
Formula 2.
For instance for propane in the top;
Step 1:
= 7.01887 +
889.864
(257.084+43.8793)
(DC Formula 1)
= 11538.5 mmHg
Step 2:
K =
Step 3:
11538.5
11251
1.0256
0.2865
= 1.0260 (DC Formula 2)

= 3.5801 (DC Formula 3)
Steps 1 to 3 were done for the propane in the bottom using the bottom pressure
instead. After which the alpha values for butane and pentane were calculated
similarly using the respective top and bottom pressures.
The alpha values were calculated using DC Formula 4.
A.B. Verasingham
Table VI.1.6: Manual Mass Balance for DC-101.

LK
HK
HNK
Chemical
Propane
Butane
Pentane
ave
3.166153
1
0.347113
LK,rect
3.3448
1
-
LK,strip
2.9581
1
-
, middle
3.125
1
0.352
DC Formula 5 was used for the bubble point calculation. Whereas, DC Formula 6
was used for the dew point calculation. The Goal Seek function in Microsoft Excel
was used to obtain xi,2 =1 and yi,3 =1 as displayed in Section VI.1.
Then Nm (minimum number of stage) was calculated by using Fenske equation;
using DC Formula 7.
0.99 0.747
log (
)
0.11 0.018
Nm =
log(3.166)
Nm = 7.2150
The new distribution of non-keys was carried out using DC Equation 14. It was
found that the non-key in the distillate was negligible (DHNK = 7.10 x 10-5).
Hence, this proved that the assumption that all the HNK is at the bottom was
acceptable.
The Fenske equation was used to calculate the stripping and rectifying stage; DC
Equation 8 and 9 respectively.
( Nm)rect
0.99 0.2724
ln
0.01 0.6439
= 3.0900
3.348
ln
0.64393 0.7470
ln
0.27243 0.0180
( Nm) strpt
32.7600
2.9581
ln
1
,
3.0900
=
,
32.7600
In order to obtain the Rm (reflux minimum) the Underwood equation was used
(DC Formula 10). The feed entering DC-101 is saturated vapour (q=0)
A.B. Verasingham
Step 1: was found using DC formula 11.

1=
3.125(0.6439) 1(0.2724) 0.352(0.0836)

+
+
3.125
1
0.352
was found by using the goal seek function in Microsoft Excel. Hence, =1.699
3 (between the LK and HK).
Step 2: Substitution of into DC Formula 10
Rm + 1 =
3.166(0.99)
1(0.01)
0.347(0)
+
+
3.166 1.699 1 1.699 0.347 1.699
Rm =1.1557
Based on the reflux ratio optimization as expressed by DC-101 Figure 2. The

best reflux ratio was deemd to be R = 2Rmin
R = 2.3110
Using DC Graph 10, Nt was found to be 9.8800.
Referring to the Kirkbride Equation; DC Formula 12, the feed entry can be
obtained.
2 0.206
m
1580.46 0.2724
0.0180
=(
[
] )
p
2067.14 0.6439
0.01
m=1.012p
1.012p+p=9.88; p=4.1300 and m = 4.9700

Thus, the feed entry point is at 5th stage.
By using the Tave = 74.37 C or 347.52 K and the OConnel constants; the
viscosity of each liquid was found using DC Formula 15.
Table VI.1.7: OConnel Equation Constants (Sinnot, 2005).
LK
HK
HNK
Chemical
Propane
Butane
Pentane
A
222.67
265.84
313.66
B
133.41
160.2
182.48
log
-1.02834
-0.89448
-0.81633
ave =
,Cp
0.093683
0.127503
0.152641
0.1246
The overall column efficiency, E,OC was then calculated using OConnel Relation;
Eo = 51 32.5 log (ave
ave
Eoc = 51 32.5 log(0.1246 x 3.1661)

Eoc = 64.127%
Fraction of Eoc = 0.6413
A.B. Verasingham
DC Formula 16 is used to obtain the actual number of stages.

0.6413 =
9.88
Na =14.584 stages (including 1 reboiler)

The actual feed entry is the 8th stage.
Calculation of L, L, V, and V
Using DC Formula 17, 18, 19, and 20;
V= 154.74 kmol/hr
V= 82.169 kmol/hr
L= 108.00 kmol/hr
L= 108.00 kmol/hr
L/V=0.8130
L/V=4.0370
The following values were extracted from HYSYS;

Table VI.1.8: Physical Properties for the Components in the Top and Bottom.
Properties
Temperature, C
Pressure, bar
Vapour Density, kg/m3
Liquid Density, kg/m3
Molecular Weight
Surface Tension, N/m
Top Column
44.86
15.00
33.39
507.50
44.23
0.004816
Bottom Column
102.3
15.40
38.04
589.30
59.88
0.004241
Column Diameter Determination

A plate spacing of 0.35 m was taken (determined through trial and error)
*Using DC Formula 21
108.00
33.39
10.508
FLV top= 154.74 507.5
FLV bottom=4.037761.035
FLV top=0.1790
FLV bottom=0.3339
Corrected Surface Tension

*Using DC formula 22 and the K1 value from DC Graph 1
K1top = 0.060 and K1 bottom = 0.045
0.0048 2
K1 (Corrected), top = 0.060 ( 0.020 )

= 0.0451
0.0042 2
Bottom K1 (Corrected), bottom = 0.045 ( 0.020 )

= 0.033
A.B. Verasingham
Vapour Flooding Velocity, Uf

507.5-33.9
33.9
Top U,f = 0.0451
Bottom U,f = 0.033
= 1.0157 m/s
589.3-38.04
38.04
= 0.8003 m/s
A flooding percentage of 80% was used.

Vapour Velocity based on net cross-sectional area, Un
Top Un = 0.8 1.0157
= 0.8126 m/s
Bottom Un = 0.8 0.8003

= 0.6403 m/s
Maximum Volumetric Flow Rate, vg

Top vg =
154.74 44.23
33.39 3600
= 0.0569 m3/s
Bottom vg =
589.30 82.169
38.04 3600
= 0.354 m3/s
Net Area, An
*Using
DC Formula 26
Top,Ac
0.0569
0.8126
Bottom,Ac =
= 0.0701 m2
0.354
0.6403
= 0.5522 m2
Downcomer is assumed to be 11% of the net area (obtained through trial and
error)
Column Cross-Sectional Area, Ac
Top, Ac
0.0701
0.8900
Bottom, Ac
= 0.0787 m2
0.5522
0.8900
= 0.6205 m2
Column Diameter, DC
0.0787 4
Top, DC =
= 0.0316 m
Bottom, DC
0.6205 4
= 0.8888 m (> 0.7 m)
A diameter of 0.95 m was taken by accounting for a 36 inch pipe.
A.B. Verasingham
Liquid Flow Pattern (Stripping Section)

Maximum volumetric liquid rate
at the bottom =
108.0099 59.8800
589.3000 3600
= 0.0031m3/s
Based on DC Graph 8; liquid-flow is a cross flow (single pass).
Provosional Plate Design
Column Diameter, Dc = 0.95 m
Column area, Ac
= 0.7089 m2
Downcomer area, Ad = 0.11 0.7089
= 0.00779 m2
Net Area, An
= 0.7089 - 0.00779
= 0.6309 m2
Active Area, Aa
= 0.7089 - (2 0.00779)
= 0.5530 m2
using DC Formula 30
using DC Formula 31
using DC Formula 32
19% of Aa was taken through trial and error.

Ah
= 0.190.5530
= 0.1051 m2
using DC Formula 3
Based on DC Graph 3, with

Weir length
Ad
Ac
=0.11, then
= 0.75 0.95
= 0.7125 m
Assumptions
Weir height, hw
Hole size
Plate thickness
50
5
5
Lw
=0.75
Dc
mm
mm
mm
< 15% of plate spacing
Check Weeping
108.01 44.23
Maximum liquid rate = (
)
3600
using DC Formula 36
= 1.3270 kg/s
70% of turndown was taken as an assumption.
Minimum liquid rate = 0.7 1.3270
= 0.9289 kg/s
At maximum how
2/3
1.3270
= 750 (589.3 0.7125)

= 16.1522 mm
At minimum how
using DC Formula 38
0.9289
2/3
=750 (589.3 0.7125)
using DC Formula 39
using DC Formula 40
=12.7339 mm; Acceptable as it needs to be at least 10mm.

At minimum rate
= 50 + 12.7339
using DC Formula 41
= 62.7339 mm
Based on DC Graph 2, K2= 30.5
A.B. Verasingham
Minimum Vapor Design Velocity, Uh,min =
30.5-0.9(25.4-5)
(38.04)0.5
using DC Formula 42
= 1.9683 m/s
Actual minimum vapour velocity (using DC Formula 43)

Uh =
0.7 0.3536
0.1050
=2.3559 m/s; Acceptable as it is above the u,h min (weep point)
Plate Pressure Drop

Ah
Aa
=0.19 and
Plate thickness
Hole diameter
= 1
using DC Formula 44
Based on DC Graph 6, Co = 0.935

Maximum vapour velocity, Uh =
0.3536
0.1051
= 3.3656 m/s
3.3656 2 38.04
589.30
Dry plate pressure drop, hd = 51 ( 0.935 )
using DC Formula 45
using DC Formula 46
= 42.6561 mm liquid
Residual head, hr =
12.5 10
589.30
= 21.2116 mm
Total drop, hr = 42.6561+21.2116 +62.7339
using DC Formula 47
using DC Formula 48
= 126.6017 mm
Initial estimation, assume that pressure drop per plate is 100 mm of water. In
actual fact, it is hard to maintain specific value of pressure since there will be
fluctuation (flow rate or to account for the membrane MR-101 failure; equipment
before DC-101).
Total Plate Pressure Drop, Pt
using DC Formula 49
-3
= 9.81 10 126.6017 589.3000 = 731.8884 Pa or 0.0073 bar

Total pressure drop= 0.0073 x 14.854 = 0.11 bar
using DC Formula 50
The assumed appropriate pressure drop deviates from calculation by a factor of

3; pressure drop taken was 0.4 bar to account for fluctuations. A pressure drop
of 0.12 bar had a < 0.9% difference in terms of k-values, alpha values and
number of stages. Hence, 0.12 bar did not deviate the manual calculation values
significantly so the initial estimate of 0.4 bar was used.
Downcomer Liquid Backup
Downcomer pressure loss, hap =50-5 =45 mm
-3
Area under apron, Aap = 0.71254010
using DC Formula 51
using DC Formula 52
=0.0285 m2 ; less than Ad = 0.0779 m2

A.B. Verasingham
1.3270
Head loss in the downcomer, hdc = 166 (589.30.0285)
using DC Formula 53
= 1.0363 mm 2mm
Back-up in downcomer, hb = 62.7339+126.6017+2
using DC Formula 54
= 191.3357 mm or 0.19134m
;acceptable <
1
(l +hw )
2 t
= 0.2
Downcomer Residence Time

tr =
0.0779 0.19134589.3
=6.6259;
1.3270
acceptable > 3s
using DC Formula 55
Entrainment Check
uv =
0.05694
=0.8126
0.0701
% of flooding=
m/s
using DC Formula 56
0.8126
=0.8000
1.0157
80%
using DC Formula 57
From DC graph 9, using Flv, bottom = 0.3339; =0.040; acceptable < 0.1
Trial Layout
Used cartridge-type construction. Allow 50 mm unperforated strip round plate
edge; 50 mm calming zones.
Based on DC Graph 4, using
Lw
=0.75;
DC
Ld
DC
= 0.17 c =100.7.
Angle substended by the edge of the plate

= 180- 100.7 = 79.3
using DC Formula 60
Mean length, unperforated edge strips

50
= 0.9500- (1000) 79.3 = 1.2458 m
using DC Formula 61
-3
Area of unperforated edge strips = 5010
1.2458
using DC Formula 62
=0.0623 m2
Mean length of the calming zone approx
= 0.7125 + 0.050 = 0.7625 m
using DC formula 63
Area of calming zones
using DC formula 64
=2 0.7625 0.05
=0.07625m2
Total area of perforation, Ap = 0.5530-0.0623-0.07625
using DC formula 65
= 0.4144 m2
A.B. Verasingham
Ah 0.1051
=
=0.2535
Ap 0.4144
Based on DC graph 5,
lp
dh
=2; acceptable as it is not < 2
Number of Holes
Area of one hole
= (
5
1000
using DC formula 68
)
-5
= 1.96410
Number of holes
m2
0.1051
1.96410
-5
using DC formula 69
= 5350 holes; to be drilled using a M6 x 1.5 thread code
size
Column Area
A=
0.952
4
= 0.7089 m2
using DC formula 70
Tower Height
H = (0.35 x 14.854) + (0.005 x 14.854) + (2 x 0.475)
using DC formula 71
= 6.2232 m (Height to Diameter ratio = 7; acceptable as less than 20)
T.Y. Kim
AIV. VI.2: SC-101 Calculation

Mass Balance
Gas flowrate of inert gas, Gm = 919.45
kmol
hr
= 0.00598184 (2 )/()
As there is no inert gases reacting with MEA in the scrubber Gm(in) and Gm(out)
are same.
Gm out = 919.45 (2 )/()
= 0.00005438 (2 )/()
Gm( ) = Lm( )
CO2 loading per mole of MEA is 0.5 at the operating condition.
Mole of MEA
1
=
=2
Mole of CO2 0.5
Assuming MEA is pure solution, Xt=0
= ( ) = 919.45(0.00598184 0.00005438) = 0.5
Lm (MEA pure) = 1838.9 /
However, MEA is not pure but 30%.
Lm (30% MEA) =
1838.9
0.3
= 0.00008157
Gb = 17157.4 kg/hr
= 4.76594 kg/s
Lb = [Lm(sol) Mr(sol)] + [Lm(MEA) Mr(MEA)]
Lb = 301579.6 kg/hr
= 83.772
kg/s
Column height
Referring to (E.Ugochukwu, 2011) the partial pressure of CO2 in aqueous 30%
MEA at the operating condition and loading of 0.5 is 8.5583 kPa (= 0.085 bar).
The operating pressure is 3.8 bar. Therefore,
mole fraction of 2 =
0.085
= 0.02
3.8
T.Y. Kim
mole fraction of 2 in liquid =
0.5 (2 )
= 0.05
0.5 (2 ) + 1 () + 8 ()
1mol MEA = 61kg
MEA: Water = 3: 7
61kg MEA: Xkg Water = 3: 7

X kg Water = 142.3kg
mole of water = 7.9 mol (= 8 mol)
slope of equilibrium line (m) =
0.28
= 0.40
0.05
90% of CO2 is removed in the scrubber therefore, 10% of it is releases as outlet

gas.
mol fraction of 2 out as vapour = 0.1 0.02 = 0.0020
yin
= 10
y
Figure AIV. VI.2.1. is brought from Figure 11.40 from (R.K.Sinnott, 2010) and it
shows the relationship between the number of stages and y1/y2 at different
m(Gm/Lm).
Figure AIV. VI.2.1.: Number of transfer units as a function of y1/y2 with

mGm/Lm parameter (R.K.Sinnott, 2010)
Table AIV. VI.2.1. shows the various NOG at y1/y2=10 and table AIV. VI.2.1.2.
shows the mole fraction in the solution for each mGm/Lm.
T.Y. Kim
Table AIV. VI.2.1.: Number of transfer units at each mGm/Lm

m(Gm/Lm)
NOG
0.60
3.80
0.7
4.5
0.8
5.1
0.9
6.3
1
8.2
1.1
18
Table AIV. VI.2.1: X1 at each mGm/Lm

m(Gm/Lm)
X1
0.8000
0.0360
0.9
0.0405
1
0.045
As shown above, the suitable number of stages is 6.3. When mGm/Lm increases
with 0.1, those between 0.8 and 1.0 show the reasonable differences in the
number of stage. Among the three values, the one from 0.8 to 0.9 requires
about 1 more stage while other one from 0.9 to 1.0 requires about 2 more
stages. Hence 0.9 is chosen. Hence,
NOG =7 stages
Column Diameter
L = 301579.6
kg
kg
= 83.77
h
s
V = 16654.91
kg
kg
= 4.63
h
s
= 2.70
kg
m
= 999.99
kg
m
L = 9.94 m. Pas = 9.94 cst = 0.00994 Nm/s2

According to (R.K.Sinnott, 2010),
4 ( )1/2
=
13.1
(Eq. AIV. VI.2.1)
The figure below shows the generalized pressure drop correlation adopted from
(R.K.Sinnott, 2010). It determines K4.
T.Y. Kim
Figure AIV. VI.2.2.: Generalized pressure drop correlation

mm(water)
Assume the pressure drop is 22 m(height of column),

=

= 0.94

4 = 0.31
= 0.65
0.31
percentage flooding =
100% = 69%
0.65
= 997.29
Intalox saddle, ceramic (38mm diameter) is used as packing material.
From table 18-5, page 18-23 of Perry 1997,
= 170 m1

= 1.089
( ) 1.089
A =
=
2
4.63
4
D=
= 2.33m
T.Y. Kim
A=
2.332 = 4.25 2
4
Packing size is 38mm. Hence, packing size to column diameter ratio is

2.33/0.038.
packing size to column diameter ratio=61.2
Column packing height by Cornells method

Operating temperature = 311K
According to (Faisal M.Khan, 2013),
2, = 2.2 (
2 0.8
)
(Eq. AIV. VI.2.2)
2.2 = 2.35 106 e
2119
(Eq. AIV. VI.2.3)

2.2 = 2.35 106 e
2119
311
= 2.58 109
(21.186 + 2373)((0.01015 + 0.0093 2.2589) + 1)

L
= exp[
]
H2O
2
(Eq. AIV. VI.2.4)
From (Faisal M.Khan, 2013),
w = 95
= 0.5
2, = 1.39 106 /
From pg599 of (R.K.Sinnott, 2010),
ScL =liquid Schmidt number=
L
D
L L
ScL = 7.14
From figure 11.43 of (R.K.Sinnott, 2010) which is shown below,

h = 0.09
T.Y. Kim
Figure AIV. VI.2.3: Factor for HL

From figure 11.41 of (R.K.Sinnott, 2010) which is shown below,
K 3 = 0.74
Figure AIV. VI.2.4: Percentage flooding correction factor

Z = NOG = 7
From (R.K.Sinnott, 2010),
0.15
= 0.305 0.5 3 (
)
3.05
(Eq. AIV. VI.2.5)
HL = 0.0581
According to (Fuller et al., 1966), the atomic and structural diffusion volume
increments are as below.
T.Y. Kim
= 16.50
= 1.98
= 5.69
= 5.48
As there are 2 carbons, 7 hydrogens, 1 nitrogen and 1 oxygen in MEA, the total
atomic diffusion volume increment is,
33 + 13.86 + 5.69 + 5.48 = 46.03
According to equation 8.21 from (R.K.Sinnott, 2010),
1
DV =
1.013 10
1.75
1
1 2
( + )
1 2
[( )3 + ( )3 ]
(Eq. AIV. VI.2.6)

Ma = 61kmol/kg
Mb = 44kmol/kg
T = 311K and P = 3.8bar
Calculating from atomic and structural diffusion volume increments given above,
= 46.03
= 26.90
DV = 2.8 106
V = 1.16 105
From pg599 of (R.K.Sinnott, 2010),
ScV =gas Schmidt number=
v
D
V V
ScV = 1.54
From figure 11.42 of (R.K.Sinnott, 2010),

h = 81
This is shown below.
T.Y. Kim
Figure AIV. VI.2.5.: Factor for Hg

L = 83.77kg/s
A = 4.3m2
=
L
= 19.71 kg/m2. s
A
1 = (
2 =
0.16
)
= 1.54
2
1.25
= 0.99
3 =
0.8
= 0.22
From equation 11.110 of (R.K.Sinnott, 2010),
HG = 1.31
HL = 0.06
HOG = + ( ( )) = 1.36
Z = HOH = 9.51
Hence, 10m packing is required.
J.K.C. Chan
AIV. VI.3: RX-101 Calculations

Table VI.3.4.3 Initial Parameter Calculation Data for ODE Equations and Other
Equipment Specification Calculation
Type of Variables
Density of Gas, o (kg/m^3)
Values
0.7680
Gas viscosity, (kg/m.s)
2.78E-05
Source
Manual Calc. (outlet mass flowr
ate/volumetric flowrate)
From HYSYS simulation
Superficial mass velocity, G

(kg/m2.s)
2.3554
Manual Calc., G= ov
Particle Loaded Density (kg/

m^3)
560
From Johnson Matthey Catalogu

e for KATALCO series
Voidage,
0.3
Diameter of particle,Dp (m)
2.50E-03
Specific Gravity, gc (m3)
Throttled Velocity, v (m/s)
3.067
From Johnson Matthey Catalogu

e for KATALCO series
Assumed velocity when velocity
is throttled by fins at entering h
ead nozzle
Cross-Sec. Area of total Tubing
= Number of tubes Ds2/4
Mass balance manual calculation
Cross-Sectional Area of total 6.46

Tubing (m2)
Total Mass Flowrate, Ft (kg/ 111428.56
h)
Tubular Mass Flowrate, Ftsm 508.79
all (kg/h)
Mass balance manual calculation
VI.3.4.3.1: Alpha and Beta Calculation

1) Calculating alpha, and beta, values in the pressure ODE equation:
o=
ogcDp
(2.3554)
( 3 ) [
150(1)
+ 1.75]
(10.3) 150(10.3)2.785
(0.7680)(1)(2.53) (0.3)3
2.53
+ 1.75(2.3554)]
=168235.0357
=
2o
(1) c P0
2(168235.0357)
6.4551(10.3)560 360
= 0.3694
J.K.C. Chan
VI.3.4.3.2: MATLAB Simulation Algorithm

2) Designing MATLAB Simulation Algorithm:
In order to simulate the desired reactor in MATLAB, the algorithm is divided into
2 scripts in which the first is PBR Function Script and the second is Execution
Script. The purpose of this algorithm is to solve the 6 ODE equations in section
(VI.1.5.1), so that final product values can be obtained together with the
pressure drop ratio in terms of weight used. (A=methane, B=ethene, C=
benzene, D= naphthalene, E= hydrogen and pd= pressure drop ratio).
(i) PBR Function file:
%Define function=pbrtrial5heat(w,y)
function dy= pbrtrial5heat (w,y)
FA=y(1);
FB=y(2);
FC=y(3);
FD=y(4);
FE=y(5);
pd=y(6);%pd equals to 'y' pressure drop term
T=y(7); %T equals to the temperature of the reactor
Finert=1.861398534;
Fto=32.69467799;
alpha=0.369609623;
Vo=735.1849048; %Initial Volumetric Flow Rate
Cto=Fto/Vo;
Ft=FA+FB+FC+FD+FE+Finert;
%Defining Rate Laws & Conc.
k1 = 144/(560);
k2 = 15120/(560) ;
k3 = 43.2^6 /(560);
%Avoiding V-term which is dependent on sigma and conversion,X term.
CA = Cto*(FA/Ft)*pd;
CB = Cto*(FB/Ft)*pd;
CC = Cto*(FC/Ft)*pd;
CD = Cto*(FD/Ft)*pd;
CE = Cto*(FE/Ft)*pd;
r1A = -k1*CA;
r1B = (1/2)*k1*CA ;
r1E = k1*CA;
r2B = -k2*CB;
r2C = (1/3)*k2*CB;
r2E = k2*CB ;
r3E = 3*k3*CB*CC;
r3D = k3*CB*CC;
r3B = -2*k3*CB*CC;
r3C = -k3*CB*CC;
rE = r1E+r2E+r3E;
rD = r3D;
rC = r2C+r3C;
rB = r1B+r2B+r3B;
rA = r1A;
%Defining pressure drop effect
pd=((-alpha/2*y(6))*(Ft/Fto));
%Defining temperature drop effect
Ta=(25+273.15);
UA=(100/1000)*(60); %unit kJ/(h.K)
CpA= 71.55;
CpB=92.61;
CpC=-30.91;
J.K.C. Chan
CpD=67.14;
CpE=30.133;
Hrx1=202280.00;
Hrx2=-74810.00;
Hrx3=-110990.00;
Hrx4=74850.00;
T=[(rA*Hrx1)+(rB*Hrx2)+(rC*Hrx3)+(rD*Hrx4)]/[(y(1)*CpA)+(y(2)*CpB)+(y(3)*CpC)+(y(4)*Cp
D)+(y(5)*CpE)];
%Remember to insert Selectivity function
%Defining dy
dy=[rA;rB;rC;rD;rE;pd;T];
(ii) Execution File:
yo=[30.15777341;0.042110341;0.30499566; 0.00019907;00.370311309;1];
%yo equals to the inlet reactant flowrates for each component and the
%ratio 1 at entering pressure
Wrange=[0.00001 50];
[w,y]=ode45(@pbrtrial5,Wrange,yo);
%Multiply 200 tubes to get the full amount produced
Ffinal(:,1)=y(:,1)*200;
Ffinal(:,2)=y(:,2)*200;
Ffinal(:,3)=y(:,3)*200;
Ffinal(:,4)=y(:,4)*200;
Ffinal(:,5)=y(:,5)*200;
Wrange2=w*200;
Conversion=1-(Ffinal(:,1)/(30.15777341*200));
VI.3.4.3.3: Space Time, Ratio of L/D Calculation & Pressure Drop

Calculation
3) From mass balance calculation (section..), the inlet volumetric flowrate is =
145389.13 m3/h and the actual volume of reactor=58.05 m3.
Therefore, Space Time, (h)
=
=
Actual Reactor Volume

Inlet Volumetric Flowrate
58.05
145389.13
= 0.3993 x 10-3 h
Calculation for ratio of diameter shell against the shell length (without head):
Ratio of L/D=
9
3
=3
Thus ratio of L/D =3:1
Calculation for exiting pressure after considering pressure drop effect of catalyst
bed:
From figure VI.3.4.2.5.6, it was found that the pressure drop ratio =0.5 (1.d.p.)
Therefore exiting pressure drop= 0.5 3.6 bar =1.8 bar
J.K.C. Chan
VI.3.4.3.4: Conversion, Selectivity and Yield Percentage of Methane

and Expected Products
Table VI.3.4.2.4 Mass Balance for Methane Reaction in RX-101
Components
Methane, CH4
Ethene, C2H4
Hydrogen, H2
Ethene, C2H4
Consumption
(kmol/h)
(At X=0.1768%)
Reaction 1
-7.38
3.69
7.38
Reaction 2
-0.03
Consumption
(kmol/h)
(At X=100%)
-6031.55
3015.775
-6031.55
3015.775
Benzene, C6H6
0.01
1005.258
Hydrogen, H2
0.03
3015.775
Ethene, C2H4
Reaction 3
-11.88
1005.258
Benzene, C6H6
-5.94
2010.516
Naphthalene, C10H8
5.94
1005.258
Hydrogen, H2
17.82
3015.774
Net Consumption
(From Product Graphs VI.3.4.5.1- VI.3.4.5.8)
Methane, CH4
-7.38
-6031.55
Ethene, C2H4
-8.24
-2010.516
Benzene, C6H6
-5.93
-3015.775
Naphthalene, C10H8
5.94
1005.258
Hydrogen, H2
25.23
12063.099
4) Conversion percentage of overall methane conversion, X (from VI.1.4.2.5:

Methane Conversion Graphs) = 0.001768 100%=0.1768%
J.K.C. Chan
5)
Selectivity percentage of hydrogen gas, SH2=
25.23
45.34
100% = 55.65 %(2 d.p.)
Selectivity percentage of ethene, SC2H4

8.24
45.34
5.93
45.34
2 4
100%
100% =18.17%
Selectivity percentage of benzene, SC6H6 =

=
6 6

100%
100% =13.01%
Selectivity percentage of naphthalene, SC10H8 =
6 6
5.94
45.34
25.23
12063.099
8.24
2010.516
5.93
3015.775
2 4
2 4
5.94
1005.258
100%
6 6
6 6
100%
100% = 0.1966%
Yield percentage of naphthalene, SC10H8 =

=
100%
100% = 0.4098% (4 d.p.)
Yield percentage of benzene, SC6H6 =

=
100% =0.2092% (4 d.p.)
Yield percentage of ethene, SC2H4 =

=
100%
100% =13.10%
6) Yield percentage of hydrogen gas, SH2 =

=
100%
10 8
10 8
100%
100%=0.5909%
J.K.C. Chan
VI.3.4.2.5: Products, Pressure Drop, Methane Conversion &

Temperature Profile Graphs
Figure VI.3.4.2.5.1:
Methane, (Component A) Flowrate (kmol/h) Versus Weight

of Catalyst (kg)
Ethene, (Component B) Flowrate (kmol/h) Versus Weight

of Catalyst (kg)
100 | A p p e n d i x
J.K.C. Chan
Figure VI.3.4.2.5.3: Benzene, (Component C) Flowrate (kmol/h) Versus Weight

of Catalyst (kg)
Figure VI.3.4.2.5.4: Naphthalene, (Component D) Flowrate (kmol/h) Versus

Weight of Catalyst (kg)
101 | A p p e n d i x
J.K.C. Chan
Hydrogen, (Component E) Flowrate (kmol/h) Versus

Weight of Catalyst (kg)
Pressure Drop Ratio, (pd) Versus Weight of Catalyst (kg)
102 | A p p e n d i x
J.K.C. Chan
Conversion of Methane (limiting reactant) Versus Weight of

Catalyst (kg)
Temperature
of Reactor Versus Weight of Catalyst (kg)
103 | A p p e n d i x
F. Prasetya
AIV. VI. 4: DC-102 Calculation

Refer to AIV.VI.I for the DC formula and graph
For DC-102, the feed containing 13 components.
Table AII.VI.4.1: List of i,ave of the components
i,ave
Component
Flowrate (kmol/hr)
CO2
0.027
112.890
N2
0.009
921.947
H2
0.058
1396.009
CH4
5.010
292.094
C2H4
0.045
93.066
C2H6
0.344
72.266
C3H6
0.002
27.917
C3H8
1.798
29.274
C4H10
0.875
10.121
C5H12
0.336
5.066
C6H6
106.711
1.000
C7H8
5.306
0.434
C10H8
7.783
0.016
The formula to calculate i,ave refers to DC formula 4. Before the distillation
column is designed, the dew and bubble point need to be approximated by
referring to DC formula 1,2,3,5 and 6.
Dew point
Pressure
Temperature
: 3.2 bar
: 48.5 oC
Table AII.VI.4.2:
Component
CO2
N2
H2
CH4
C2H4
C2H6
C3H6
C3H8
C4H10
C5H12
C6H6
C7H8
C10H8
Total
Bubble point
Pressure
Temperature
Dew Point Calculation Table

K value
Xi
34.698
8.25572E-05
451.583
2.11868E-06
787.870
7.66871E-06
115.972
0.004519164
29.362
0.00016043
21.207
0.00169541
6.670
3.0077E-05
7.053
0.026672058
1.935
0.047305183
0.836
0.040520643
0.127
0.877267094
0.046
0
0.001
0
0.998262404
: 4.2 bar
: 137.7 oC
104 | A p p e n d i x
F. Prasetya
Table AII.VI.4.3: Bubble Point Calculation Table

Component
K value
Yi
CO2
52.653
0
N2
269.851
0
H2
365.633
0
CH4
105.990
0
C2H4
42.599
0
C2H6
34.698
0
C3H6
16.213
0
C3H8
16.710
0
C4H10
7.099
0
C5H12
4.057
0.000405668
C6H6
1.093
0.972288797
C7H8
0.554
0.024768453
C10H8
0.038
0.002479072
Total
0.999941991
Then Nm (minimum number of stage) was calculated by using Fenske equation

(refer to Dc formula 7).
0.0339 0.8897
log (
)
0.1116 0.0001
Nm =
log(4.9660)
Nm = 4.930
Then the new component distribution can be obtained by referring to DC formula
14.
Table AII.VI.4.4: New Component Distribution
Component
Distillate (kmol/hr)
Bottom (kmol/hr)
CO2
0.027
0.000
N2
0.009
0.000
H2
0.058
0.000
CH4
5.010
0.000
C2H4
0.045
0.000
C2H6
0.344
0.000
C3H6
0.002
0.000
C3H8
1.798
0.000
C4H10
0.874
0.001
C5H12
0.324
0.012
C6H6
1.067
105.644
C7H8
0.001
5.305
C10H8
0.000
7.783
After the new component distribution, some of the components will have very
small flowrate. Hence, for some of the component, it is assumed to be 0.
The next step is to obtain the Rm (reflux minimum) by using Underwood. Theta
105 | A p p e n d i x
F. Prasetya
must be found in order to calculate the Rm. Theta can be found by using DC
formula 11. Since the feed is a mixture thus 1-q is 0.092. Substitute the
equation thus the theta obtained is 5.007. The theta value must be in the range
between alpha value of light key and heavy key.
Rm +1=3.890
Rm =2.890
As it has been stated in the individual report section, the reflux value will be
taken as 1.5 times reflux minimum. Hence,
R=4.335
The number of minimum stage can be obtained by referring to DC Graph 10.
Nm = 9 stages.
After obtaining Reflux, overall efficiency needs to be calculated in order to
determine the actual number of stages.
-0.245
Eoc =0.492(L ave )
Eoc =0.492(0.4544.966)-0.245
Eoc =0.454
Referring DC formula 16, the actual number of stages can be obtained
91
0.454
Na =18 stage, add 1 for reboiler stages
Na =19 stage ( including 1 reboiler)
Na =
Next step is to determine the entry point. Referring to Kirkbride Equation (DC
formula 12, the feed entry can be obtained
2 0.206
m
118.745 0.832
0.0001
=(
[
] )
p
9.560
0.003
0.1116
m=0.306p
m+p=19; m=5
Thus, the feed entry point is at 5th stage.
Calculation of L, L, V, and V
Referring to DC formula 17, 18, 19, and 20, all of value can be obtained. Thus
L= 41.438 kmol/hr
V= 50.997 kmol/hr
L/V=0.813
L= 157.845 kmol/hr
V= 39.100 kmol/hr
L/V=4.037
106 | A p p e n d i x
F. Prasetya
To calculate the diameter of the column, several parameters need to be obtained

Table AII.VI.4.5: Density for Top and Bottom Part of Distillation Column
Density (kg/m3)
Feed
Top
Bottom
Vapour
8.181
10.673
10.508
Liquid
788.745
807.598
761.035
Column diameter calculation

Referring to DC formula 21
10.673
FLV top=0.813
807.598
FLV top=0.111
10.508
FLV bottom=4.037
761.035
FLV bottom=0.474
Correction for surface tension refers to DC formula 22 and obtained the K1
value from DC graph 1
Top K1 (Corrected)
0.004 2
= 0.070 ( 0.020)
= 0.051
Bottom K1 (Corrected)
0.015 2
= 0.041 (0.020)
= 0.038
Calculation of vapour flooding velocity, uf (refers to DC Formula 23)

Uf, TOP
= 0.051
807.598-10.673
10.673
= 0.440 m/s
Uf, BOT = 0.038
761.035-10.508
10.508
= 0.324 m/s
The distillation has been design at 80% maximum flooding. Hence, at maximum
flowrate, the Vapour Velocity (Un) based on net cross-sectional area for top and
bottom are (refers to DC formula 24)
Top Un = 0.8 0.440
= 0.352 m/s
Bottom Un
= 0.8 0.324
= 0.259 m/s
107 | A p p e n d i x
F. Prasetya
Maximum flowrate (refers to DC formula 25)

Top max. flowrate
34.577 50.997
10.763 3600
= 0.046 m3/s
39.100 82.109
Bottom max. flowrate
= 10.508 3600
= 0.085 m3/s
Net area required (refers to DC formula 26)

Top
0.046
0.352
= 0.130 m2
0.085
Bottom
= 0.259
= 0.327 m2
Take 18% of downcomer, column cross section area are (refers to DC formula 27)
Top
0.130
0.820
= 0.159 m2
0.327
Bottom
= 0.820
= 0.399 m2
Column diameter (refers to formula 28)

Top
0.159 4
= 0.450 m
Bottom
0.399 4
= 0.712 m
Based on BS 1600, the diameter of the column is 0.762 m
Liquid Flow Pattern (refer to DC formula 29)
Maximum volumetric liquid rate
157.845 82.019
761.035 3600
= 0.004 m3/s
Provosional Plate Design (refer to DC formula 30 to 33)

Column Diameter, Dc = 0.762 m
Column area, Ac
= 0.456 m2
Downcomer area, Ad = 0.18 0.456
= 0.082 m2
Net Area, An
= 0.456 - 0.082
= 0.373 m2
Active Area, Aa
= 0.456 - 2 0.082
= 0.291 m2
Take 6% of Aa as the first trial for hole area, Ah
= 0.060.291
= 0.018 m2
108 | A p p e n d i x
F. Prasetya
Weir length (refer to DC formula 34 to 35)

From DC Graph 3, the ratio between weir length and column diameter
Ad
Lw
=0.18
thus
=0.82
A
D
c
Weir length
= 0.820 0.790
= 0.624 m
Check weeping
Maximum liquid rate (DC formula 36)
= (
157.845 82.109
)
3600
= 3.596 kg/s
Assumption
1. Weir height
= 50mm
2. Hole diameter = 5mm
3. Plate diameter = 5 mm
Take 80% of turndown as assumption
Minimum liquid rate (refer to DC formula 38)
= 0.8 3.596
= 2.877 kg/s
2/3
0.944
At maximum how (refer to DC formula 39) =750 (0.625 761.305)

=38.528 mm
At minimum how (refer to DC formula 40)
0.755
2/3
=750 (0.625 761.305)
=33.203 mm
At minimum rate (refer to DC formula 41) = 50.000 + 33.203
= 83.203 mm
From DC graph 2, K2= 30.5
Minimum Vapor Design Velocity, Uh,min (refers to DC formula 42)
Uh,min =
30.5-0.9(25.4-5)
=3.745 m/s
(10.508)0.5
Actual minimum vapour velocity (refer to DC formula 43)

Uh =
0.8 0.085
0.018
Uh =3.873 m/s
Hence, the minimum operating rate will be above weep point.
Plate Pressure Drop
Dry plate drop
Maximum vapour velocity through holes (refer to DC formula 45)
109 | A p p e n d i x
F. Prasetya
Uh =
0.085
0.018
Uh =4.841 m/s
From DC Graph 6, Co can be obtained.
AH
=0.1
Ap
and plate diameter/hole diameter =1,
thus Co =0.84
Refer to DC formula 46, hd can be obtained

2
4.481
10.508
)
0.840 761.035
hd =23.389 mm
hd =51 (
Residual Head (refer to DC formula 47)

hr =
12.5 10
761.035
=16.425 mm
Total pressure drop (refer to DC formula 46)

hr =50.000+38.528+23.389+16.425=128.342 mm
Initial estimation, assume that pressure drop per plate is 100 mm of water.
However, it has been mentioned in the report that the pressure drop is larger
than the actual one because in the real application, it is hard to maintain specific
value of pressure since there will be fluctuation.
Total pressure drop per plate (actual value, refer to dc formula 48)
-3
Pt =9.81 10 128.342 761.035

Pt =958.17 Pa 0.01 bar
Total pressure drop for the column = 19 0.01 bar
= 0.19 bar
However, as it has been mentioned in the report, pressure drop of 0.053 bar per
tray is taken due to fluctuation of the pressure that can be occurred in the
column.
Downcomer liquid backup
Downcomer pressure loss (refer to DC formula 51)
hap =50-10=40 mm
Area under apron (refer to DC formula 52 to 53)
-3
Aap =0.6254010 =0.025 m2

2
3.596
hdc =166 (
) =5.934 mm
0.025761.035
110 | A p p e n d i x
F. Prasetya
Round up to 6 mm
Back-up in downcomer (refer to DC formula 54)
hb =50+38.521+105.610+6=222.870 mm
hb must be lesser compare to
1
(l +hw )=
2 t
1
(l +hw )
2 t
250 mm
Hence, plate spacing is acceptable

Check residence time (refer to DC formula 55)
tr =
0.082 0.228761.035
=3.8 4 s
3.596
The residence time is greater than 3s. Hence, it is acceptable

Entrainment check (refer to DC formula 56 and 57)
uv =
0.085
=0.227 m/s
0.374
0.018
% of flooding=0.324 =0.69969.9%
Flv, bottom =0.474
From DC graph 9, =0.030 , well below 0.1
Trial layout (refer to DC formula 58 to 70)
Use cartridge-type construction. Allow 50 mm unperforated strip round plate
edge; 50 mm calming zones.
From DC graph 4, at
Lw
=0.82,
DC
c =110
Angle substended by the edge of the plate =180-110=70

50
Mean length, unperforated edge strips = 0.762- (1000)

= 0.870 m
Area of unperforated edge strips
70
180
-3
=5010 0.870
=0.043 m
Mean length of the calming zone approx

Area of calming zones
= 0.625 + 0.050
= 0.675 m2
=0.675 0.05
=0.067 m2
Total area of perforation, Ap

Ap =0.291-0.043-0.067=0.181 m2
111 | A p p e n d i x
F. Prasetya
Ah 0.018
=
=0.097
Ap 0.181
From DC graph 5,
Area of one hole
Lp
dh
=2.8 (still in the range between 2.5 and 4)

= (0.0025)2
-5
= 1.9610
Number of holes
m2
0.0175
-5
1.9610
= 892 holes
Tower Height (refer to DC formula 71)

Tower height = (18 x 0.45) + (18 x 0.005) +3
= 11.190 m
112 | A p p e n d i x
Y.S.E. Soh
AIV. VI. 5: DC-103 Calculation

Refer to AIV.VI.I for the DC formula and graph
Material Balance:
Benzene recovery in distillate: 98.5%
Example calculation:
Benzene in distillate = 0.985 X 105.644
= 104.1 kmol/h
Benzene in bottom
= FBenzene - DBenzene
= 105.6 104.1
= 1.585 kmol/h
HK (Toluene, C7H8) in distillate: 0.003
= 0.003 , DTotal= Total distillate flow
= .
[0.001 + 0.012 + 104.1 + ]
DToluene= 0.313 kmol/h
Assumption: C4H10 and C5H12 only appear in distillate whereas C10H8 only appears
in bottom product.
LK (Benzene, C6H6) in bottom=
Component
C4H10
C5H12
C6H6
C7H8
C10H8
Sum
Feed (kg/h)
0.06
0.86
8252.06
488.81
997.50
9739.28
Benzene purity (wt %)
1.585
14.36
= 0.11
Distillate (kg/h)
0.06
0.86
8128.28
28.85
0.00
8158.05
Bottom (kg/h)
0.00
0.00
123.78
459.96
997.50
1581.23
8128.28
100%
8158.05
= 99.6 wt %
113 | A p p e n d i x
Y.S.E. Soh
Feed data:
Flow= 118.74 kmol/h, pressure= 2.2 bar, temperature= 113.0 oC
z,i
C4H10
0.000
C5H12
0.000
C6H6
0.890
C10H8
0.066
C7H8
0.045
Sum
1.000
-Using DC formula 1
Component
log P*
1.295
0.892
0.423
-1.368
0.034
x
y
0.000
0.000
0.000
0.000
0.803
0.967
0.136
0.003
0.061
0.030
1.000
1.000
and 2, K value of individual components can be found.
Using the formula: =
( 1)+1
P*
19.707
7.795
2.649
0.043
1.082
K
8.958
3.543
1.204
0.019
0.492
, the vapour fraction of the feed can be found.
Vapour fraction, (1-q) = 0.528

Light key= benzene and heavy key= toluene
Using DC formula 1, 2, 3, 5 and 6 to perform dew point, bubble point and
alpha calculation:
At 1.8 bar, dew point is 97.4 oC (370.5 K)
Components
C4H10
C5H12
C6H6
C10H8
C7H8
SUM
y
0.000
0.000
0.997
0.000
0.003
1.000
log P*
1.17
0.75
0.26
-1.65
-0.16
P*
14.62
5.56
1.81
0.02
0.68
x=y/K
8.12
3.09
1.00
0.01
0.38
0.000
0.000
0.994
0.000
0.008
1.002
21.373
8.133
2.639
0.033
1.000
At 2.3 bar, bubble point is 164.2 oC (437.3 K)

Components
C4H10
C5H12
C6H6
C10H8
C7H8
SUM
x
0.000
0.000
0.110
0.542
0.348
1.000
log P*
1.655
1.292
0.891
-0.600
0.574
Fraction of vapour, (1-q) = 0.528

L
P*
45.168
19.567
7.772
0.251
3.752
;R
K
19.638
8.507
3.379
0.109
1.631
Y=Kx
0.000
0.000
0.373
0.059
0.567
1.000
12.037
5.215
2.071
0.067
1.000
= 0.986
= RD
= 0.986*104.386
= 102.874 kmol/h
114 | A p p e n d i x
Y.S.E. Soh
= L+ qF
= 102.874 + (0.4718*118.745)
= 158.904 kmol/h
= D+ L
= 104.386 + 102.874
= 207.260 kmol/h
= V- (1-q)F
= 207.260- (0.5282*118.745)
= 144.544 kmol/h
DC formula 7: Nm
log[(
0.997 0.348
)(
)]
0.003 0.110
log 2.338
= 8.19
Using DC formula 4, 10 and 11:
Components
,avg
C4H10
15.50
C5H12
6.362
C6H6
2.283
C10H8
0.048
C7H8
1.000
SUM
= 1.041
1-q
0.000
0.000
1.635
-0.003
-1.101
0.531
Rm+1
0.000
0.000
1.832
0.000
-0.074
1.758
Rm= 0.758
OConnell column efficiency, Eoc
= 0.492 ( )0.245
= 0.492[0.242 2.063]0.245
= 0.584
DC formula 16: Nactual=
16.06
0.584
= 28
DC formula 14 (Distribution of non-key component):

W of C4H10
0.001
0.31 21.3712.04 8.19
1+[
][
]
4.99
1
= 2.15E-12
W of C5H12
0.012
0.31 8.135.21 8.19
1+[
][
]
4.99
1
= 4.11E-08
D of C10H8
7.783
1.59 2.642.07 8.19
1+[
][
]
104.06 0.030.07
= 2.10E-11
115 | A p p e n d i x
Y.S.E. Soh
DC formula 12 (Number of rectifying and stripping stage)
14.36 0.045 0.110 2 0.206

=[
(
)(
) ]
= 1.585
104.39 0.89 0.003

Solving: m= 1.585 p and m+p = 28
Number of stages in rectifying section, m= 17
Number of stages in stripping section, p= 11
Feed entering stage= 17th (last stage of rectifying section)
Physical Properties (From HYSYS)
Distillate
o
Temperature, C
100.3
3
v, kg/m
4.745
l, kg/m3
787.033
Molecular weight
78.151
Surface tension, N/m
0.0183
Bottom
151.9
5.870
827.911
103.905
0.0181
DC formula 21:
FLV, top
102.874
4.745
(787.033)
207.260
= 0.039
FLV, bottom
158.904
5.870
(827.911)
144.544
= 0.092
DC graph 1: Top K1= 0.11, bottom K1= 0.10
Constant to be multiplied to K1= 0.825 (as hole area/ active area= 0.065)
DC formula 22:
Top K1
0.0183 0.2
)
0.02
=(
0.825 0.11
= 0.0892
Base K1
0.0191 0.2
)
0.02
= (
0.825 0.10
= 0.0817
DC formula 23 (Vapour flooding velocity):
Top uf
787.0334.745
4.745
= 0.0892
= 1.145 m/s
Base uf
852.9355.962
5.962
= 0.0817
=0.974 m/s
116 | A p p e n d i x
Y.S.E. Soh
Design for 85% flooding at maximum flowrate, using DC formula 24:

Top uf
= 0.85*1.145
= 0.973 m/s
Base uf
= 0.85*0.974
= 0.828 m/s
DC formula 25 (Maximum volumetric flowrate):

Top
207.26078.151
4.7453600
= 0.948 m3/s
Base
144.544110.122
5.9623600
= 0.742 m3/s
DC formula 26 (Net area required):
Top
0.948
0.973
= 0.975 m2
Base
0.742
=0.828
= 0.895 m2
DC formula 27 (Column cross sectional area, AC):

Top
0.975
=0.935
= 1.042 m2
Base
0.895
=0.935
= 0.958 m2
DC formula 28 (Column diameter, Dc):

Top
1.0424
= 1.152 m
Base
0.9584
= 1.104 m
-By rounding off column diameter to the nearest standard head size,
Column diameter (Dc)
= 1.2192 m
DC formula 70:
Column area (Ac)
= 1.167 m2
117 | A p p e n d i x
Y.S.E. Soh
DC formula 30:
Downcomer area (Ad)
= 0.0759 m2 (at 6.5% of column area)
DC formula 31:
Net area (An)
= 1.167- 0.0759
= 1.092 m2
DC formula 32:
Active area (Aa)
= 1.167- (2*0.0759)
= 1.016 m2
DC formula 33:
Hole area (Ah)
= 0.065*1.016 (6.5% of active area)

= 0.066 m2
DC graph 3:
Weir length
Other specifications: Weir height
= 0.780 m2
= 50 mm
Hole diameter = 5 mm
Plate thickness= 5 mm
DC formula 36 (Liquid flow pattern):
Maximum volumetric liquid rate in rectifying section= 2.84E-3 m3/s
Maximum volumetric liquid rate in stripping section= 5.70E-3 m3/s
From DC graph 8, single pass cross flow can be used.
Check for weeping
Maximum liquid rate
DC formula 37:
Min liquid rate (At
60% turn-down)
DC formula 38:
Maximum how
DC formula 39:
Top
102.874 78.151
3600
= 2.233 kg/s
Bottom
0.6*2.233
= 1.340 kg/s
0.6*4.861
= 2.916 kg/s
750(
2
2.233
)3
787.033 0.780
=17.74 mm
Minimum how
DC formula 40:
At min rate, hw+how

DC formula 41:
K2
DC graph 2:
750(
2
1.340
)3
787.033 0.780
158.904110.122
3600
= 4.861 kg/s
750(
2
4.861
)3
852.935 0.780
=28.23 mm
750(
2
2.916
)3
852.935 0.780
=12.62 mm
=20.08 mm
50+12.62= 62.62 mm
50+20.08= 70.08 mm
30.3
30.5
118 | A p p e n d i x
Y.S.E. Soh
Min design vapour

Velocity
DC formula 42:
Actual min vapour
Velocity
DC formula 43:
[30.3 0.9(25.4 5)]
[30.5 0.9(25.4 5)]
4.745
= 5.48 m/s
5.962
= 4.97 m/s
0.6 0.948
0.066
=8.62 m/s
0.6 0.742
0.066
=6.74 m/s
-Both the actual minimum vapour velocity of top and bottom section are greater
than the minimum design vapour velocity (above weep point). Hence, design is
satisfactory.
Plate pressure drop
Top
Maximum vapour
velocity through hol
es
DC formula 45:
0.948
=
0.066
Bottom
0.742
=
0.066
14.36 m/s
C0
DC graph 6:
0.815
Dry plate pressure

drop (hd)
DC formula 46:
14.36 2 4.745
51(
) (
)
0.815 787.033
=95.50 mm liquid
Residual head (hr)

DC formula 47:
12500
787.033
11.23 m/s
0.815
11.23 2 5.962
51(
) (
)
0.815 852.94
= 67.72 mm liquid
= 15.88 mm liqui
Total plate pressure 95.50 + 15.88

+ 50.00 + 17.74
drop (ht)
= 179.12 mm liquid
DC formula 48:
= 0.018 bar
Total pressure drop of column
12500
852.94
= 14.66 mm liquid
67.72 + 14.66
+ 50.00 + 28.23
= 160.61 mm liquid
= 0.016 bar
= (17*0.018) + (10*0.016)
= 0.47 bar
Downcomer Liquid Back Up

DC formula 51:
hap = 50- 10
= 40 mm
DC formula 52: Area under apron, Aap = 0.780 * (0.040)

= 0.0312 m2
-As Aap (0.0312 m2) is smaller than Ad (0.0759 m2), use Aap in DC formula 53.
119 | A p p e n d i x
Y.S.E. Soh
DC formula 53 (Head loss in the downcomer):

Top: hdc
2.233
= 166[787.030.0312]2
= 1.37 mm
= 1.5 mm
Bottom: hdc
4.861
= 166[852.940.0312]2
= 5.54mm
= 6 mm
DC formula 54 (Downcomer backup):

Top, hb
= 50 + 17.74 +179.12 + 1.5

= 248.36 mm
Bottom, hb
= 50 + 28.23 + 160.61 + 6
= 244.84 mm
0.5* (600 + 50) = 325mm [Both downcomer backup for top and bottom section
are satisfactory as it is smaller than half of the sum of plate spacing and weir
height.]
DC formula 55 (Residence time):
Top: tr
0.07590.248787.03
2.233
= 6.6 s
Bottom: tr
0.07590.244852.94
4.861
= 3.3 s
-Both residence times are greater than 3 s, thus design is satisfactory.
Entrainment
Top
Flooding velocity(uv)
DC formula 56:
% Flood
DC formula 57:
Fractional entrainment
DC graph 9:
0.948
1.092
Bottom
= 0.869 m/s
0.869
1.145
0.05
100% = 75.9%
0.742
1.092
= 0.679 m/s
0.679
100%
0.974
=69.7%
0.019
Perforated Area
Cartridge-type construction is used. Unperforated strip round plate edge is 50
mm and calming zones is 50 mm wide.
120 | A p p e n d i x
Y.S.E. Soh
DC formula 58:
0.780
= 1.219 = 0.64
From DC graph 4,
= 81o
= 0.12, Lh= 0.146 m
Chord length= 1.2192 0.146

= 1.073 m
DC formula 60:
Angle subtended by the edge of the plate= 180- 81= 99o
DC formula 61:
Mean length of unperforated edge strips
= (1.2192- 0.05) *(99/180)

= 2.02 m
DC formula 62:
Area of unperforated edge strips= 0.05*2.02 = 0.101 m2
DC formula 63:
Approximate mean length of calming zone= 0.780+ 0.05 = 0.830 m
DC formula 64:
Area of calming zone= 2(0.830*0.05) = 0.083 m2
DC formula 65:
Total area for perforation, Ap = 1.016- 0.101- 0.083 = 0.832 m2
DC formula 66:
0.066
=
= 0.079
0.832
DC graph 5:
= 3.1 (Satisfactory as it is within the range of 2.5 to 4.0)
Hole pitch, lp= 15.5 mm

Number of holes
DC formula 68:
Area of one hole= (0.0025)2 = 1.964E-5 m2
DC formula 69:
Number of holes=
0.066
1.9645
= 3363
DC formula 70:
Tower height= (0.6*27) + (0.005*27) + 3 = 19.335 m
Height to diameter ratio=
19.335
1.2192
=15.86
121 | A p p e n d i x
AV. Detailed HAZOP Study
HAZOP
FV-101
Study Title: HAZOP
Drawing No.:
HAZOP Team: Kim Tae Yeon
Part considered: FV-101
Page: of
Date: 14.Apr.2016
Meeting Date: 14.Mar.2016
Design intent: To flash the feed gas from water

No Parameter Guideword Deviation Cause
Stream No.: S-1
Consequence
Safeguards
Actions
1.1.i. Install low flow

alarm
Regular maintenance
1.2.i. Regular
maintenance
Install low flow alarm
2.1.i. Regular
maintenance of the
pipe lines
1.1.a. Partial shutdown of the pretreatment section.

No
1.1.
No flow
1.1.1. Line
rupture
1.1.I. No flow
to HE-101
Less
1.2.
Less flow
1.2.1. Pipe line

partially
blocked
1.2.I. Less
flow to HE-101
More
2.1.
High
pressure
2.1.1. Blockage
in pipe line
2.1.I. Pipe
rupture
Less
2.2.
Low
pressure
2.2.1. Fouling
2.2.2. Leakage
from the pipe
line
2.2.I. Reverse
flow from HE101
2.2.i. Install an nonreturn valve
2.2.a. Check and

replace the leakage
part
No
1.1.
No flow
1.1.1. Line
rupture
1.1.I. No flow
to HE-101

alarm
1.1.ii. Regular
maintenance
Flow
Pressure
2.1.a. Open of relief

valve
Stream No.: S-2

1
Flow
122 | A p p e n d i x
Less
1.2.
Less flow
1.2.2. Pipe line

partially
blocked
1.2.I. Less
flow to HE-101
1.2.ii. Install low flow

alarm
1.2.iii. Refer1.1.ii
1.2.b. Open control

valve
1.2.c. Refer1.1.a
More
2.1.
High
pressure
2.1.1. Blockage
in pipe line
2.1.I. Pipe
rupture
2.3.i. Refer1.1.ii

valve
Less
2.2.
Low
pressure
Pressure
More
3
Temperatu
re
Less
3.1.
High
Temperat
ure
3.2.
Low
Temperat
ure
2.2.1. Fouling
2.2.2. Leakage
from the pipe
line
3.1.1. Tempera
ture of cooling
water is hotter
than usual
3.2.1. Tempera
ture of cooling
water is cooler
than usual
2.2.I. Reverse
2.4.i. Install an nonflow from HEreturn valve
101
2.2.a. Check and

replace the leakage
part
3.1.I. More
flow in S-03
3.1.i. Install
temperature sensitive
alarm
3.1.a. Increase
cooling water flowrate
3.2.I. Less
flow in S-03
3.2.i. Refer3.1.i
3.2.a. Decrease
1.1.I. Increase
in moisture
content in the
flow
1.1.i. Install flow

indicator and alarm
1.1.a. Increase
in HE-101.
1.2.I. Pressure
build up in FV101
1.2.II. Low
yield
1.2.i. Install
pressure indicator and
alarm
1.2.ii. Regular
Maintenance of the
pipe lines
1.2.a. Open control

valve.
Stream No.: S-3

No
1.1.
No flow
Flow
Less
1.2.
Less flow
1.1.1. High
temperature in
S-02
1.1.2. Line
rupture
1.2.1. Low
temperature in
S-02
1.2.2. Pipe
partially
blocked
1.2.3. Leakage
from the pipe
123 | A p p e n d i x
More
2
Pressure
Less
2.1.
High
pressure
2.1.1. Blockage
in pipe line
2.1.I. Pipe
rupture
2.1.i. Refer1.2.ii

valve
2.2.
Low
pressure
2.2.1. Higher
pressure drop
due to fouling
2.2.2. Leakage
from the pipe
line
2.2.I. High
pressure build
in FV-101
2.2.II. Reverse
flow from FV101
2.2.a. Check and

replace the leakage
part
1.1.
High flow
1.1.1. High
temperature in
S-02
1.1.I. Decreas
e in moisture
content in the
flow
1.1.i. Install flow

indicator and alarm
1.1.a. Increase
in HE-101.
1.2.
Less flow
1.2.1. Low
temperature in
S-02
1.2.2. Pipe
partially
blocked
1.2.3. Leakage
from the pipe
1.2.I. Level
increases in FV101
1.2.i. Install level

indicator and alarm
1.2.ii. Regular
Maintenance of the
pipe lines
1.2.a. Open control

valve
2.1.1. Blockage
in pipe line
2.1.I. Pipe
rupture
2.1.i. Regular
maintenance of the
pipe lines

valve
2.2.1. Higher
pressure drop
due to fouling
2.2.I. Reverse
flow
2.2.a. Check and

replace the leakage
part
Stream No.: S-4 and S-5

More
Flow
Less
More
2
Pressure
Less
2.1.
High
pressure
2.2.
Low
pressure
124 | A p p e n d i x
DH-101 & DH-102

Study Title: HAZOP
Drawing No.:
Part considered: DH-101 and DH-102
Design intent: To dehydrate the feed
No Parameter Guideword Deviation
No
1.1.
No flow
Less
1.2.
Low flow
More
2.1
Higher
pressure
Flow
Pressure
Page: of
Date: 14.Apr.2016
Cause
Consequence
1.1.I. No feed
1.1.1. Line
to dehydrator
rupture
1.1.II. Line
1.1.2. Large
rupture
blockage
1.1.III. Feed
1.1.3. Large
escapes
leakage
1.1.IV. Dehydra
tor failure
1.2.I. Less
1.2.1. Leakage feed to
1.2.2. Partial
dehydrator
blockage
1.2.II. Dehydra
tor failure
2.1.I.
Wrong
2.1.1 Blockage pressure
in the pipe
difference
2.1.2
Higher 2.1.II.
Higher
temperature
temperature
2.1.3.
High 2.1.III.
More
flowrate
feed
to
dehydrator
Safeguards
Actions
1.1.i. Install flow

indicator and alarm
1.1.ii. Regular
maintenance
1.1.a. Replace fault

part
1.2.i. Refer 1.1.i

1.2.ii. Refer 1.1.ii
1.2.a. Refer 1.1.a

1.2.b. Open control
valve
2.1.i. Refer 1.1.i

2.1.a. Refer 1.1.a

2.1.b. Close control
valve
125 | A p p e n d i x
Less
2.2
Lower
pressure
2.2.I.
Refer
2.2.1 Leakage
2.1.I
2.2.2
Lower 2.2.II.
Lower
2.2.i. Refer 1.1.i
Temperature
temperature
2.2.3
Low 2.2.III.
Less
flowrate
feed
to
dehydrator
2.2.a. Refer 1.1.a

2.2.b. Open control
valve
Stream No.: S-8
No
1.1.
No flow
Less
1.2.
Low flow
More
2.1
Higher
pressure
Flow
Pressure
1.1.1. Line
rupture
1.1.2. Large
blockage
1.1.3. Large
leakage
1.2.1. Leakage
1.2.2. Partial
blockage
1.1.I. Line
rupture
1.1.II. Feed
escapes
1.2.I. Pressure
build up in the
dehydrator
2.1.I.
Wrong
2.1.1 Blockage pressure
in the pipe
difference
2.1.2
Higher 2.1.II.
Higher
temperature
temperature
2.1.3.
High 2.1.III.
More
flowrate
heat load to
heat exchanger
1.1.i. Install flow

indicator and alarm
1.1.ii. Regular
maintenance

part
1.2.i. Refer 1.1.i

1.2.a. Refer 1.1.a

1.2.b. Open control
valve
2.1.i.
Install
flow
2.1.a. Refer 1.1.a
indicator and alarm
2.1.ii.
Regular
valve
maintenance
126 | A p p e n d i x
Less
2.2
Lower
pressure
2.2.I.
Wrong
pressure
2.2.1 Leakage
difference
2.2.2
Lower
2.2.II.
Higher 2.2.i. Refer 2.1.i.
Temperature
temperature
2.2.ii. Refer 2.1.ii.
2.2.3
Low
2.2.III.
Less
flowrate
heat load to
heat exchanger
2.2.a. Refer 1.1.a

2.2.b. Open control
valve
Stream No.: S-9
No
1.1.
No flow
Less
1.2.
Low flow
More
2.1
Higher
pressure
Flow
Pressure
Less
2.2
Lower
pressure
1.1.1. Line
rupture
1.1.2. Large
blockage
1.1.3. Large
leakage
1.2.1. Leakage
1.2.2. Partial
blockage
2.1.1. Blockage
in the pipe
2.1.2.
Higher
temperature
2.1.3.
High
flowrate
2.2.1. Leakage
2.2.2.
Lower
Temperature
2.2.3.
Low
flowrate
1.1.I. Line
rupture
1.1.II. Feed
escapes
1.1.i. Install flow

indicator and alarm
1.1.ii. Regular
maintenance

part
1.2.I. Pressure
build up in the
dehydrator
1.2.i. Refer 1.1.i

1.2.a. Refer 1.1.a

1.2.b. Open control
valve
2.1.I.
Wrong
pressure
difference
2.1.II.
Higher
temperature
2.1.i.
Install
flow
2.1.a. Refer 1.1.a
indicator and alarm
2.1.ii.
Regular
valve
maintenance
2.2.I.
Wrong
pressure
2.2.i. Refer 2.1.i.
difference
2.1.II.
Higher
temperature
2.2.a. Refer 1.1.a

2.2.b. Open control
valve
127 | A p p e n d i x
More
3.1
Higher
Temperat
ure
3.1.1.
cooling
supplied
Less
agent
Less
3.2
Lower
Temperat
ure
3.2.1.
cooling
supplied
More
agent
Temperatu
re
3.1.I.
Subsequent
equipment
failure
3.1.II
High
pressure
3.1.III
High
flowrate
3.2.I.
Subsequent
separation
failure
3.2.II.
Low
flowrate
3.2.III.
Low
pressure
3.1.i.
Install
temperature indicator
3.1.a. Supply
and alarm
cooling agent
3.1.ii.
Regular
maintenance
3.2.i. Refer 3.1.i.

3.2.a.
Supply
cooling agent
more
less
128 | A p p e n d i x
MR-101 & TB-101

Study Title: HAZOP
Drawing No.:
Part considered: MR-101 and TB-101
Page: of
Date: 14.Apr.2016
Design intent: To Separate propane from feed gas

Stream No.: S-10
No
1.1
No flow
1.1.1. Line
rupture
1.1.2. Large
blockage
1.1.3. Large
leakage
Less
1.2
Less flow
1.2.1. Leakage
1.2.2. Partial
blockage
Flow
Consequence
1.1.I. No feed
to
membrane
1.1.II. Line
rupture
1.1.III. Feed
escapes
1.1.IV. Subsequ
ent equipment
failure
1.2.I. Less
feed to
membrane
1.2.II. Subsequ
ent equipment
failure
Safeguards
Actions
1.1.i. Install flow

indicator and
alarm
1.1.ii. Regular
maintenance

part
1.2.i. Refer 1.1.i

1.2.a. Refer 1.1.a

1.2.b. Open control
valve
129 | A p p e n d i x
Pressure
More
2.1
Higher
pressure
2.1.1 Blockage
in the pipe
2.1.2 Higher
temperature
2.1.3. High
flowrate
Less
2.2
Lower
pressure
2.2.1 Leakage
2.2.2 Lower
Temperature
2.2.3 Low
flowrate
2.1.I. Wrong
pressure
difference
2.1.II. Higher
temperature
2.1.III. More
feed to
membrane
2.2.I. Refer
2.1.I
2.2.II. Lower
temperature
2.2.III. Less
feed to
membrane
2.1.i. Refer 1.1.i

2.1.a. Refer 1.1.a

2.1.b. Close control v
alve
2.2.i. Refer 1.1.i

2.2.a. Refer 1.1.a

2.2.b. Open control
valve
1.1.I. Line
rupture
1.1.II. Feed
escapes
1.1.III.Subsequ
ent equipment
failure
1.1.i. Install
pressure difference
indicator and alarm
1.1.ii. Regular
maintenance

part
1.1.b. Open close
valve
1.2.I. Subsequ
ent equipment
failure
1.2.i. Refer 1.1.i

1.2.a. Refer 1.1.a

1.2.b. Open control
valve
No
1.1.
No flow
Less
1.2.
Less flow
Flow
1.1.1. Wrong
pressure
difference
1.1.2. Line
rupture
1.1.3. Large
blockage
1.1.4. Large
leakage
1.2.1. Wrong
pressure
difference
1.2.2. Leakage
1.2.3. Partial
blockage
130 | A p p e n d i x
Pressure
More
2.1
Higher
pressure
2.1.1 Blockage
in the pipe
2.1.2 Higher
temperature
2.1.3. High
flowrate
Less
2.2
Lower
pressure
2.2.1 Leakage
2.2.2 Lower
Temperature
2.2.3 Low
flowrate
2.1.I. Wrong
pressure
difference
2.1.II. Higher
temperature
2.1.III.
Overheat heat
exchanger
2.2.I. Refer
2.1.I
2.2.II. Lower
temperature
2.2.III. Heat
exchanger
failure
2.1.i. Refer 1.1.i

2.1.a. Refer 1.1.a

2.1.b. Close control v
alve
2.2.i. Refer 1.1.i

2.2.a. Refer 1.1.a

2.2.b. Open control
valve
131 | A p p e n d i x
DC-101
Study Title: HAZOP
Drawing No.:
Part considered: DC-101
Page: of
Date: 14.Apr.2016
Design intent: To separate and purify propane

No Parameter Guideword
Deviation Cause
S-12
More
1.1
More flow
1.1.1 High
liquid level in
reboiler
1.1.2 Failure
in reboiler
control valve
1.1.I. Affects
separation in
distillation
column if
beyond the
limit.
1.1.II. Flooding
of column.
1.1.III.High
pressure in
column.
1.2
Less flow
1.2.1 Pipe
blockage and
leakage
1.2.2 Reboiler
failure
1.2.3 Utility
temperature
too high
1.2.4 Failure
in reboiler
control valve
1.2.I. Pressure
builds up in
pipe, resulting
in pipe rupture
and explosion.
1.2.II. Fewer
products.
1.2.III.Larger
vapour flow
back
Flow
Less
Consequence
Safeguards
Actions
1.1.i. Install flow

indicator.
1.1.a. Close control

valve partially.
1.1.b. Increase steam
flow.
1.2.i. Temperature
indicator.
1.2.ii. Flow indicator.
1.2.a. Use detector to

detect leakage or
blockage in pipe.
1.2.b. Decrease
steam flow Change
reboiler control valve
manual mode and
open control valve.
132 | A p p e n d i x
Reverse
No
Temperatu
re
More
1.3
Reverse
flow
1.3.1 Malfunc
tion of
throttling valve
1.3.I. Damage
to reboiler.
1.4.I. Release
of hydrocarbon
1.4.1 Pipe
to surrounding.
rupture.
1.4.II. Fire and
1.4
1.4.2 Failure explosion if
No flow
in
bottom ignition source
control valve
is present.
1.4.III.Pressure
build-up
1.1.1 Failure
of steam
controlling
valve.
2.1.I. Higher
1.1.2 Higher
vapour flow
2.1 High
steam
2.1.II. Entrainm
feed
temperature to ent and flooding
temperat
reboiler
2.1.III.Level in
ure
1.1.3 Malfunc reflux drums
tion of
increases.
throttling valve
causing high
pressure feed.
1.3.i. Install by-pass

valve.
1.3.a. Close valve in

current line and
switch to by-pass line.
1.4.i. Install flow

indicator.
1.4.a. Check bottom

control valve
1.4.b. Emergency
shut down and
evacuation if needed.
2.1.i. Temperature
indicator
2.1.ii. Flow indicator
2.1.iii. Install level
controller and level
alarm.
2.1.a. Decrease
steam flow to reboiler
2.1.b. Close valve in
current line and
133 | A p p e n d i x
Less
Pressure
More
2.2.1 Failure
of steam
controlling
valve in .
2.2.2 Lower
2.2 Low
steam
feed
temperature to
temperat
reboiler
ure
2.2.3 Malfunc
tion of
throttling valve
causing low
pressure feed.
2.2.I. High
liquid flow
Weeping occur.
2.2.II. Level in
reflux drums
decreases.
2.1.i
Temperature
indicator.
2.2.ii Install by-pass
valve.
2.2.iii Install
level
alarm.
2.2.a. Increase steam

flow to reboiler
2.2.b. Close valve in
current line and
1.1.1 Throttli
ng valve
3.1 High
failure.
feed
1.1.2 Pipe
pressure
blockage due
to fouling
3.1.I. Liquid
will not flow
down and
causes
entrainment.
3.1.II. Flooding
in the rectifying
stage.
3.1.III.Higher
pressure in
column.
3.1.IV. Pipe
rupture and
emission of
hydrocarbon to
surrounding.
3.1.i. Pressure
controller.
3.1.ii. Install
pressure alarm.
3.1.iii. Install
pressure relief valve.
3.1.iv. Install by-pass
valve.
3.1.a. Open by-pass

valve.
3.1.b. Open pressure
relief valve.
3.1.c. Emergency
shut down and
evacuation.
134 | A p p e n d i x
Less
1.2.1 Throttli
3.2 Low ng valve
feed
failure.
pressure
1.2.2 Pipe
leakage.
3.2.I. Backflow
of feed.
3.2.II. Release
of hydrocarbon
to environment.
1.1.1 Low
temperature in
column
1.1.2 Low
1.1
cooling water
More flow
temperature
1.1.3 Low
steam
temperature
1.2.1
High
temperature in
column
1.2.2
High
1.2 Less cooling water
flow
temperature
1.2.3
High
steam
temperature
1.1.I. High
liquid level in
reboiler.
1.1.II. Higher
bottom product
flow
1.1.III.Higher
flowrate
3.2.i
controller.
Pressure
3.2.a. Open by-pass

3.2.ii Install pressure valve.
alarm.
3.2.b. 2. Emergency
shut down and
3.2.iii Install by-pass evacuation.
valve.
S-20
More
Flow
Less
1.2.I
Lower
liquid level in
reboiler
1.2.II.
Lower
bottom product
flow.
1.2.III.
Lower
flowrate
1.1.i. Install
temperature
indicator.
1.1.a. Open bottom

product control
valve.
1.1.b. Increase steam
flow
1.2.i. Install
temperature
indicator.
1.2.a Reduce opening

of
bottom
product
control valve.
1.2.b Decrease steam
flow
135 | A p p e n d i x
No
1.3
flow
1.3.I Release of
hydrocarbon to
surrounding.
1.3.1 No feed
1.3.II Result in
No to
fire if ignition 1.3.i
Install
1.3.2 Pipeline
source
is indicator
rupture
present.
1.3.III
Explosion
flow
1.3.a Unlikely.
S-18
More
Flow
Less
1.1.I
Higher
vapour flow in
1.1.1 High
stripping
steam flow to
region.
reboiler
1.1.II
Might
1.1 More
1.1.2 High
affect
flow
steam
separation
in
temperature
column
1.1.3 High
1.1.III
Might
flow
result
in
entrainment or
flooding
1.2.I
Lower
1.2.1
Low vapour flow in
steam flow to stripping
1.2 Less reboiler
region.
flow
1.2.2
Low 1.2.II
Might
steam
affect
temperature
separation
in
1.2.3 Low flow column
1.1.i.
Install
temperature indicator 1.1.a. Reduce steam
1.2.ii
Install
flow flow
indicator
1.2.i
Install
temperature indicator 1.2.a Increase steam
1.2.ii
Install
flow flow
indicator
136 | A p p e n d i x
Temperatu
re
More
Less
2.1
Higher
temperat
ure
2.1.1 High
steam flow to
reboiler
2.1.2 High
steam
temperature
2.1.3 Failure in
steam
controlling
valve
2.2
Lower
temperat
ure
2.2.1
Low
steam flow to
reboiler
2.2.2
Low
steam
temperature
2.2.3 Failure in
steam
controlling
valve
2.2.I
Low
column
temperature
2.2.II
Lower
vapour flow in
column.
2.2.III
Might
affect
separation
in
column
1.1.1 Column
high
temperature
1.1.I High level

in reflux drum.
1.1.II More
distillate flow.
2.1.I High
column
temperature
2.1.II Higher
vapour flow in
column.
2.1.III Might
affect
separation in
column
2.1.i Install
2.1.ii Install
temperature alarm
high (TAH)
2.1.a
flow
2.2.i Install
2.2.ii Install
temperature alarm
low (TAL)
2.2.a Increase steam

flow
1.1.i Install
temperature indicator.
1.1.ii Install
temperature alarm
high (TAH).
1.1.a Increase cooling

water flow.
1.1.b Reduce steam
flow
Reduce
steam
S-13 and S-14
Flow
More
1.1 More
flow
137 | A p p e n d i x
Less
Temperatu
re
Pressure
1.2.1 Column
1.2 Less low
flow
temperature
1.2.I Low level

in reflux drum.
1.2.II Less
distillate flow.
2.1.I Reflux
flow lower
temperature.
2.1.II Decrease
pressure of
column.
Less
2.1.1 Column
2.1 Low low
temperat temperature
ure
2.1.2 Steam
valve failure
Less
3.1.1 Column
low
3.1 Low
temperature
pressure
3.1.2 Low
vapour flow
3.1.I Lower flow
More
1.1.1 More
flow in S-71
1.1.2 Low
cooling water
temperature
1.1.3 High
cooling water
flowrate
1.1.I Higher
reflux flow to
column.
1.1.II Might
affect
separation in
column.
1.1.III Increase
in pump duty
1.2.i Install
1.2.ii Install
temperature alarm
low (TAL).
1.2.a Decrease
cooling water flo.
1.2.b Increase steam
flow
2.1.i Install
2.1.ii Install pressure
indicator.
2.1.iii Install
temperature alarm
low (TAL).
2.1.a Decrease
cooling water flow.
flow.
3.1.i Install pressure

indicator.
alarm low (TAL).
3.1.a Decrease
cooling water flow
flow
S-16 and S-17
Flow
1.1 More
flow
1.1.i Install flow

indicator.
1.1.a Decrease
cooling water flow.
flow
138 | A p p e n d i x
Less
Temperatu
re
Less
1.2 Low
flow
1.2.1 Less flow

in S-71
1.2.2 High
cooling water
temperature
1.2.3 Low
cooling water
flowrate
1.2.I Lower
reflux flow to
column.
1.2.II Might
affect
separation in
column.
1.2.i Install flow

indicator.
1.2.a. Increase steam

flow
2.1 Low
temperat
ure
2.1.1 Low
cooling water
temperature
2.1.2 Low
cooling water
flowrate
2.1.3 Cooling
water valve
failure
2.1.I Cooler
reflux flow back
to column.
2.1.II Decrease
in column
temperature
2.1.III Might
affect
separation in
column
2.1.i Install
2.1.a Decrease
cooling water flow
1.1.I Higher
flowrate of
distillate.
1.1.II Overflow
in storage tank.
1.1.III No reflux
flow back to
column.
1.1.i Install flow

indicator.
1.1.ii Install level
indicator at storage
tank.
1.1.iii Install level
alarm high (LAH) at
storage tank.
1.1.iv Install back-up
pump
1.1.v Regular
maintenance on pump
1.1.a Check
temperature of
column.
flow to reboiler.
1.1.c Check condition
of pump.
S-15
Flow
More
1.1.1 High
level in reflux
drum
1.1 More 1.1.2 High
flow
temperature of
column
1.1.3 Pump
failure
139 | A p p e n d i x
Less
Temperatu
re
More
1.2 Less
flow
2.1 High
temperat
ure
1.2.1 Low level

in reflux drum.
1.2.2 Low
temperature of
column
1.2.3 Pipeline
leakage
1.2.4 Low feed
flowrate
1.2.I Lower
flowrate of
distillate.
1.2.i Install flow

indicator.
1.2.ii Regular
maintenance.
1.2.a Check
temperature of
column.
flow to reboiler.
of pipelines.
2.1.1 Cooling
water valve
failure
2.1.2
Condenser
failure
2.1.I High
temperature of
benzene to
storage.
2.1.II
Formation of
benzene vapour
in storage tank.
2.1.III High
pressure in
storage tank.
2.1.i Install
2.1.ii Install
temperature alarm
2.1.iii Install pressure
alarm high (PAH) to
storage tank.

water flow.
2.1.b Check condition
of condenser
1.1.I Increase
feed to .
1.1.II Decrease
in distillate flow.
1.1.i Install
temperature and
pressure indicator
to .
1.1.ii Regular
maintenance on
reboiler.
1.1.a Check
temperature and
pressure of column.
1.1.b Check feed
flowrate
1.1.c Increase steam
flow
1.1.d Check reboiler
condition
S-19
Flow
More
1.1 More
flow
1.1.1 Low
temperature
and pressure
in column
1.1.2 Steam
valve failure
1.1.3 Higher
feed flowrate
1.1.4 Reboiler
failure
140 | A p p e n d i x
Less
Temperatu
re
Less
1.2 Less
flow
2.1
Lower
temperat
ure
1.2.1 High
temperature
and pressure
in column
1.2.2 Steam
valve failure
1.2.3 Lower
feed flowrate
1.2.4 Reboiler
failure
2.1.1 Steam
valve failure
2.1.2 Reboiler
failure
1.2.I Decrease
feed to .
1.2.II Increase
in distillate flow.
1.2.i Install
temperature and
pressure indicator
to .
1.2.ii Regular
maintenance on
reboiler.
1.2.a Check
temperature and
pressure of column.
flow
1.2.c Check feed
flowrate
condition
2.1.I Higher
feed
temperature
to .
2.1.II Affects
separation in
2.1.i Install
2.1.ii Install
temperature alarm.
2.1.iii Regular
maintenance on
reboiler.

flowrate.
2.1.b Check reboiler
condition
141 | A p p e n d i x
SC-101
Study Title: HAZOP
Drawing No.:
Part considered: SC-101
Page: of
Date: 14.Apr.2016
Design intent: Absorption of CO2 from feed by MEA

Deviation Cause
Stream No.: S-23
1.1.1. Blockag
e
1.1.2. Burst
1.1.
1.1.3. Large
No
No flow
leak
1.1.4. Incorrec
t pressure
difference
Flow
More
Less
Consequence
Safeguards
Actions
1.1.I. No
product
1.1.II. Reaction
is affected
1.1.III.Flamma
ble gas escapes
1.1.i. Install flow

detector and alarm
1.1.ii. Regular
maintenance
1.1.a. Partial shutdown of the scrubber

1.1.b. Re-design for
the pressure
difference
1.1.c. Isolate the
faulty parts
1.2.
More flow
1.2.1. High
temperature
1.2.2. High
pressure
1.2.3. Incorrec
t pressure
difference
1.2.I. Inefficie
nt CO2 removal
1.2.II. High
pressure
1.2.III.High
temperature
1.2.IV. Explosio
n of scrubber
1.2.i. Install flow

detector and alarm
1.2.a. Partial closure

of control valve
1.3.
Less flow
1.3.1. Partial
blockage
1.3.2. Small
rupture
1.3.3. Minor
leak
1.3.I. Less
yields
1.3.i. Install flow

detector and alarm
1.3.ii. Regular
maintenance
1.3.a. Isolate faulty

parts
1.3.b. Partial shutdown of scrubber
142 | A p p e n d i x
More
2.1.I. Ineffecti
ve CO2 removal
2.1.II. Rupture
2.1.III.Explosio
n of scrubber
2.2.
Lower
pressure
2.2.1. Small
rupture
2.2.2. Minor
leak
2.2.3. Lower
flowrate
2.2.4. Lower
feed
temperature
2.2.I. Reverse
flow
2.2.II. Ineffecti
ve absorption of
CO2 by MEA
2.2.III.Quality
of reaction is
affected
2.2.i. Install
alarm
2.2.ii. Install
automatic feed
controller
2.2.a. Operate
pressure controller
3.1.1. Heat
exchanger, HE103 failure
3.1.2. Higher
pressure
3.1.I. Explosio
n of scrubber
3.1.II. Ineffecti
ve CO2 removal
3.1.III.Reaction
affected
3.1.IV. Higher
flowrate
3.1.V. Higher
pressure
3.1.i. Install
and alarm
3.1.a. Isolate
equipment failures
control valve
3.1.c. Emergency
shut-down
3.1.d. Provide more
cooling agent
Pressure
Less
2.1.
Higher
pressure
2.1.1. Blockag
e
2.1.2. Higher
flowrate
2.1.3. Higher
temperature
2.1.i. Install
alarm
2.1.ii. Install
automatic feed
controller
2.1.iii. Install
pressure relief/safety
valves
Temperatu
re
More
3.1.
Higher
Temperat
ure
2.1.a. Open pressure

control valve
relief valve
143 | A p p e n d i x
Less
3.2.
Lower
Temperat
ure
3.2.1. Heat
exchanger, HE103 failure
3.2.2. Lower
pressure
1.1.
No flow
1.1.1. Blockag
e
1.1.2. Burst
1.1.3. Large
leak
1.1.4. Incorrec
t pressure
difference
3.2.I. Ineffecti
ve CO2 removal
3.2.II. Lower
flowrate
3.2.III.Lower
pressure
3.2.i. Install
and alarm
3.2.a. Provide less

cooling agent
3.2.b. Partial closure
of pressure control
valve
3.2.c. Emergency
shut down of scrubber
1.1.i. Install flow

detector and alarm
1.1.ii. Regular
maintenance

relief valve of
scrubber
1.1.c. Isolate faulty
part
1.2.i. Install flow

detector and alarm
1.2.ii. Regular
maintenance

parts
2.1.i. Install
alarm
2.1.ii. Install
valves

control valve
Stream No.: S-24 & S-25
No
1
Flow
Less
Pressure
More
1.2.
Less flow
2.1.
Higher
pressure
1.2.1. Partial
blockage
1.2.2. Small
rupture
1.2.3. Minor
leak
2.1.1. Blockag
e
2.1.2. Higher
flowrate
2.1.3. Higher
temperature
1.1.I. Level
increases in
scrubber
1.1.II. Flamma
ble gas escapes
1.1.III.Pressure
increases
1.1.IV. Explosio
n
1.2.I. Level
increases
1.2.II. Flamma
ble gas escapes
1.2.III.Explosio
n
2.1.I. High
pressure in
scrubber
2.1.II. Level
decreases
144 | A p p e n d i x
2.2.
Lower
pressure
2.2.1. Small
rupture
2.2.2. Minor
leak
2.2.3. Lower
flowrate
2.2.4. Lower
feed
temperature
No
1.1
No flow
1.1.1. Blockag
e
1.1.2. Burst
1.1.3. Large
leak
1.1.4. Incorre
ct pressure
difference
1.1.I. Reaction
is affected
1.1.II. MEA lost
1.1.i. Install flow

detector and alarm
1.1.ii. Regular
maintenance

the pressure
difference
1.1.c. Isolate the
faulty parts
More
1.2
More flow
1.2.1. High
pressure
1.2.I. Level
increases in
scrubber
1.2.i. Install flow

detector and alarm

of control valve
1.3
Less flow
1.3.1. Partial
blockage
1.3.2. Small
rupture
1.3.3. Minor
leak
1.3.I. Inefficie
nt CO2 removal
1.3.i. Install flow

detector and alarm
1.3.ii. Regular
maintenance
1.3.a. Open control

valve
Less
2.2.I. Reverse
flow
2.2.II. Level
increases
2.2.i. Install
alarm
2.2.ii. Install
automatic feed
controller
2.2.a. Operate
pressure controller
Stream No.: S-39
Flow
Less
Stream No.: S-40
145 | A p p e n d i x
Flow
No
More
1.1
No flow
1.1.1. Blockag
e
1.1.2. Burst
1.1.3. Large
leak
1.1.4. Incorre
ct pressure
difference
2.1
Higher
pressure
2.1.1. Blockag
e
2.1.2. Higher
flowrate
2.1.3. Higher
temperature
2.2
Lower
pressure
2.2.1. Small
rupture
2.2.2. Minor
leak
2.2.3. Lower
flowrate
2.2.4. Lower
feed
temperature
Pressure
Less
1.1.I. Flamma
ble gas escapes
2.1.I. Higher
flow
2.1.II. Scrubber
pressure
decreases
2.1.III.Inefficie
nt separation
2.2.I. Reverse
flow
2.2.II. Lower
flow
2.2.III.Less
product
2.2.IV. Scrubber
pressure
increases
1.1.i. Install flow

detector and alarm
1.1.ii. Regular
maintenance

the pressure
difference
1.1.c. Isolate the
faulty parts
2.1.i. Install
alarm
2.1.ii. Install
valves

control valve
2.2.i. Install
alarm
2.2.ii. Install
automatic feed
controller
2.2.a. Operate
pressure controller
146 | A p p e n d i x
SU-101
Study Title: HAZOP
Drawing No.:
Part considered: SU-101
Design intent: Store and control level of MEA to SC-101
Deviation Cause
Stream No.: S-37 & S-38
1.1.1. Blockag
e
1.1.2. Burst
1.1
1.1.3. Large
No
No flow
leak
1.1.4. Incorrec
t level
1
Flow
detection
1.2.1. Fault in
pump
1.2
More
1.2.2. Incorrec
More flow
t level
detection
Page: of
Date: 14.Apr.2016
Consequence
Safeguards
Actions
1.1.I. No MEA
make up
1.1.II. Level in
SU-101
decreases
1.1.III.Inefficie
nt CO2 removal
1.1.i. Install flow

detector and alarm
1.1.ii. Regular
maintenance

the pressure
difference
1.1.c. Isolate the
faulty parts
1.2.1. Level
increases
1.2.i. Install flow

detector and alarm

of control valve
147 | A p p e n d i x
Less
Pressure
More
1.3
Less flow
2.1.
Higher
pressure
1.3.1. Partial
blockage
1.3.2. Small
rupture
1.3.3. Minor
leak
1.3.4. Incorrec
t level
detection
1.3.5. Pump
failure
1.3.I. Level
decreases
1.3.II. Less
CO2 removal
1.3.i. Install flow

detector and alarm

parts
1.3.c. Partial closure
of control valve
2.1.1. Blockag
e
2.1.2. Higher
temperature
2.1.I. Rupture
2.1.i. Install
alarm
2.1.ii. Install
automatic feed
controller
2.1.iii. Install
valves
2.1.a. Open control

valve
1.1.1. Blockag
e
1.1.2. Burst
1.1.3. Large
leak
1.1.4. Incorrec
t level
detection
1.2.1. Fault in
pump
1.1.I. No MEA
recycle
1.1.II. Level in
SU-101
decreases
1.1.III.More
make up MEA
used
1.2.I. Level
increases
1.1.i. Install flow

detector and alarm
1.1.ii. Regular
maintenance

the pressure
difference
1.1.c. Isolate the
faulty parts
1.2.i. Install flow

detector and alarm

of control valve
Stream No.: S-35 & 36
No
1.1.
No flow
More
1.2.
More flow
Flow
148 | A p p e n d i x
1.3.I. Level
decreases
1.3.II. Less CO2
removal
1.3.i. Install flow

detector and alarm

parts
1.3.c. Partial closure
of control valve
2.1.1. Blockag
e
2.1.2. Higher
temperature
2.1.I. Rupture
2.1.II. Leakage
of MEA
2.1.i. Install
alarm
2.1.ii. Install
automatic feed
controller
2.1.iii. Install
valves
2.1.a. Open control

valve
More
3.1.
Higher
Temperat
ure
3.1.1. Heat
exchanger
failure
3.1.2. Higher
pressure
3.1.I. Explosio
n
3.1.II. Higher
flowrate
3.1.III.Higher
pressure
3.1.IV. Separati
on affected
3.1.i. Install
and alarm
Less
3.2.
Lower
Temperat
ure
3.2.1. Heat
exchanger
failure
3.2.2. Lower
pressure
3.2.I. Lower
flowrate
3.2.II. Lower
pressure
3.2.III.Separati
on affected
3.2.i. Install
and alarm
Less
Pressure
1.3.1. Partial
blockage
1.3.2. Small
rupture
1.3.3. Minor
leak
1.3.4. Pump
failure
More
1.3.
Less flow
2.1.
Higher
pressure
Temperatu
re
3.1.a. Isolate
equipment failures
control valve
3.1.c. Emergency
shut-down
3.1.d. Provide more
cooling agent
3.2.a. Provide less
cooling agent
of pressure control
valve
3.2.c. Emergency
shut down of scrubber
149 | A p p e n d i x
ST-101
Study Title: HAZOP
Drawing No.:
Part considered: ST-101
Page: of
Date: 14.Apr.2016
Design intent: Strip CO2 out of MEA

Deviation
Stream No.: S-26
No
1.1.
No flow
1.1.1. Blockage
1.1.2. Burst
1.1.3. Large
leak
More
1.2.
More
flow
1.2.1. High
temperature
1.2.2. High
pressure
Flow
Pressure
Cause
More
2.1.
Higher
pressure
2.1.1. Blockage
2.1.2. Higher
flowrate
2.1.3. Higher
temperature
Consequence
Safeguards
Actions
1.1.I. No
stripping occurs
1.1.II. CO2 and
MEA escapes
1.2.I. High
pressure
1.2.II. High
temperature
1.2.III.Explosio
n
1.1.i. Install flow

detector and alarm
1.1.ii. Regular
maintenance
1.1.a. Partial shutdown

1.1.b. Isolate the
faulty parts
1.2.i. Install flow

detector and alarm

of control valve
2.1.i. Install
alarm
2.1.ii. Install
automatic feed
controller
2.1.iii. Install
valves

control valve
relief valve
2.1.I. Ineffecti
ve CO2 removal
2.1.II. Rupture
2.1.III.Explosio
n of scrubber
150 | A p p e n d i x
2.2.1. Small
rupture
2.2.2. Minor
leak
2.2.3. Lower
flowrate
2.2.I. Reverse
flow
More
3.1.
Higher
Tempera
ture
3.1.1. Heat
exchanger
failure
3.1.2. Higher
pressure
3.1.I. Explosio
n
3.1.II. Ineffecti
ve stripping
3.1.III.Higher
flowrate
3.1.IV. Higher
pressure
3.1.i. Install
and alarm
Less
3.2.
Lower
Tempera
ture
3.2.1. Heat
exchanger
failure
3.2.2. Lower
pressure
3.2.I. Ineffecti
ve stripping
3.2.II. Lower
flowrate
3.2.III.Lower
pressure
3.2.i. Install
and alarm
1.1.I. Level in
ST-101
increases
1.1.II. No MEA
recycle
1.1.III.No CO2
stored
1.1.i. Install flow

detector and alarm
1.1.ii. Regular
maintenance
Less
2.2.
Lower
pressure
Temperatu
re
2.2.i. Install
alarm
2.2.ii. Install
automatic feed
controller
2.2.a. Operate
pressure controller
3.1.a. Isolate
equipment failures
control valve
3.1.c. Emergency
shut-down
3.1.d. Provide more
cooling agent
3.2.a. Provide less
cooling agent
of pressure control
valve
3.2.c. Emergency
shut down
Flow
No
1.1.
No flow
1.1.1. Blockag
e
1.1.2. Burst
1.1.3. Large
leak

1.1.b. Isolate the
faulty parts
151 | A p p e n d i x
No
1.1.
No flow
More
1.2.
More flow
Flow
1.1.1. Blockag
e
1.1.2. Burst
1.1.3. Large
leak
1.2.1. High
temperature
1.2.2. High
pressure
1.1.I. No MEA
recycled to
stripper
1.1.i. Install flow

detector and alarm
1.1.ii. Regular
maintenance

1.1.b. Isolate the
faulty parts
1.2.I. Level
increases in RE102

detector
1.2.a. Partially close

control valve
1.1.I. No MEA
back to stripper
1.1.II. MEA
escapes
1.1.i. Install flow

detector and alarm
1.1.ii. Regular
maintenance

1.1.b. Isolate the
faulty parts
1.1.I. Escape
of CO2
1.1.i. Install flow

detector and alarm
1.1.ii. Regular
maintenance

1.1.b. Isolate the
faulty parts
1.2.I. High
pressure

detector

control valve
1.1.I. MEA lost
1.1.i. Install flow

detector and alarm
1.1.ii. Regular
maintenance

1.1.b. Isolate the
faulty parts

1
Flow
No
1.1
No flow
1.1.1. Blockag
e
1.1.2. Burst
1.1.3. Large
leak
Stream No.: S-30
No
1.1
No flow
More
1.2
More flow
Flow
1.1.1. Blockag
e
1.1.2. Burst
1.1.3. Large
leak
1.2.1. High
temperature
1.2.2. High
pressure
Stream No.: S-33

1
Flow
No
1.1
No flow
1.1.1. Blockag
e
1.1.2. Burst
1.1.3. Large
leak
152 | A p p e n d i x
Less
1.2
Less flow
1.2.1. Blockag
e
1.2.2. Lower
pressure
1.2.I. Level
increases

detector

control valve
1.1
No flow
1.1.1. Blockag
e
1.1.2. Burst
1.1.3. Large
leak
1.1.I. Overhea
t of heat
exchanger, HE106
1.1.i. Install flow

detector and alarm
1.1.ii. Regular
maintenance

1.1.b. Isolate the
faulty parts
Stream No.: S-35

1
Flow
No
More
2.1
Higher
Temperat
ure
2.1.1. Heat
exchanger
failure
2.1.2. Higher
pressure
2.1.I. Scrubbin
g affected
2.1.II. Overhea
t
2.1.i. Install
and alarm
Less
2.2
Lower
Temperat
ure
2.2.1. Heat
exchanger
failure
2.2.2. Lower
pressure
2.2.I. Ineffecti
ve scrubbing
2.2.II. Lower
pressure
2.2.i. Install
and alarm
Temperatu
re
2.1.a. Isolate
equipment failures
control valve
2.1.c. Emergency
shut-down
2.1.d. Provide more
cooling agent
2.2.a. Provide less
cooling agent
of pressure control
valve
2.2.c. Emergency
shut down
153 | A p p e n d i x
F-101 & F-102

Study Title: HAZOP
Drawing No.:
Part considered: F-101 and F-102
Page: of
Date: 14.Apr.2016
Design intent: To heat the feed for reaction

More
1.1
High
Temperat
ure
Less
1.2
Low
Temperat
ure
Temperatu
re
Consequence
1.1.I More flow

1.1.1Temperatu
to furnace
re of cooling
1.1.II
water is hotter
Overheating of
than usual
furnace
1.2.I Less flow
1.1.2Temperatu
to furnace
re of cooling
1.2.II
More
water is cooler
energy required
than usual
for furnace
Safeguards
Actions
1.1.i
Install
water flowrate
alarm
1.2.i Refer 1.1.i
1.2.a
Decrease

alarm
1.1.ii. Regular
maintenance
1.1.b. Partial shutdown of the pretreatment section.

alarm
1.2.ii. Refer1.1.ii
1.2.a. Open control

valve
1.2.b. Refer1.1.a
No
1
1.1.
1.1
No flow
1.1.1. Line
rupture
1.2.
Less flow
1.2.1. Pipe line

partially
blocked
Flow
Less
1.1.II. No flow
to subsequent
reaction
1.1.III.Heat
loss
1.1.IV. No yield
1.1.V. Reaction
failure
1.2.I. Less
flow to reactor
1.2.II. Low
yield
154 | A p p e n d i x
More
2.3.
High
pressure
2.1.2. Blockage
in pipe line
2.1.3. High
temperature
2.1.4. More
flow
Less
2.4.
Low
pressure
2.2.3. Fouling
2.2.4. Leakage
from the pipe
line
More
3.1.
High
Temperat
ure
3.1.1. Tempera
ture of cooling
water is hotter
than usual
Less
3.2.
Low
Temperat
ure
3.2.1. Tempera
ture of cooling
water is cooler
than usual
Pressure
Temperatu
re
2.1.II. Pipe
rupture
2.1.III.Explosio
n of reactor
2.1.IV. High
temperature
2.2.II. Reverse
flow
2.2.III.Inefficie
nt reaction
2.2.IV. Low
yield
3.1.I. More
flow
3.1.II. High
pressure
3.1.III.Explosio
n of reactor
3.2.I. Less
flow
3.2.II. Low
yield
3.2.III.
Inefficient
reaction
2.3.ii. Refer1.1.ii
2.1.b. Open of relief

valve
2.4.ii. Install an nonreturn valve
2.2.b. Check and

replace the leakage
part
3.1.i. Install
alarm
3.1.a. Supply less

fuel/close control
valve
3.2.i. Refer3.1.i
3.2.a. Supply more

fuel/open control
valve
155 | A p p e n d i x
RX-101 & RX-102

Study Title: HAZOP
Drawing No.:
HAZOP Team: Joel Chan
Part considered: RX-101 and RX-102
Page: of
Date: 14.Apr.2016
Design intent: Conversion of feed to products

Deviation
Cause
S-43
No
1.1. No Flow
Flow
Less
1.2.
Flow
1.1.1.
Pipe
rupture
Consequence
1.1.I.
Loss of
feed into RX-101
1.1.II.
Overheating of
line RX-101 that
may lead to
thermal
meltdown and
explosion
Safeguards
Actions
1.1.i. Install flow

transmitter (FT431) to indicate
no flow in
1.1.a. Partial shutstream S-43
downof the reactors
section
1.1.ii. Regular
maintenance of
the pipelines
1.2.i. Install flow

1.2.I.
Less feed transmitter (FT1.2.1. Pipe line
into RX-101
431) to indicate
partially blocked
less
flow
in 1.2.a. Partial shutLess
1.2.II. May not stream S-41
down of the reactor
1.2.2. Leakage of
achieve
section
the pipe line
the desired
1.2.ii.
Regular
output for RXmaintenance of
101
the pipelines
156 | A p p e n d i x
1.3.I.
More 1.3.1. Abnormality Temperature drop
in SC-101 operation becomes
more
significant
1.3.i. Install flow

controller
(FIC-431) to
reduce flow
into RX-101
1.3.ii. Regular
maintenance
of the
pipelines
2.1.i. Install
pressure low
alarm (PAL441)
2.1.ii. Regular
maintenance
of the
pipelines
More
1.3.
Flow
Less
2.1.1.
fouling
2.1.
Low
2.1.2.
Pressure
from
pipeline
More
2.2.I.
Explosion 2.2.i. Install
of RX-101 may
pressure high
2.2.1. Blockage in
occur due to high
alarm (PAH2.2.
High
pipeline
volumetric
441)
Pressure
2.2.2. Abnormality expansion
of 2.2.ii. Regular
in SC-101 operation tubing side and
maintenance
exposing with fuel
of the pipe
gases at shell side
lines
Pipeline
2.1.I. Production
Leakage rate of RX-101 will
ruptured reduce
1.3.a. Partial shutdown of the reactor

section
1.3.b. Flow reduced
by control valve (CV132)
2.1.a.
Check
and
replace the rupture
pipeline
Pressure
2.2.a. Opening of
pressure
relieve
valve (PRV-107)
157 | A p p e n d i x
Less
3.1.1 Abnormality
3.1.I Production
in furnace, F-101 &
3.1.
Low
rate of RX-101 will
F-102 operation
Temperature
reduce
Temperatu
re
More
3.2.1 Abnormality
3.2.
High in furnace, F-101
Temperature & F-102 operation
3.2.I Explosion
of RX-101 may
occur due to
thermal meltdown
of tubing side and
exposing with fuel
gases at shell side
3.1.i Install
low
temperature
alarm,(TAL-432)
3.1.ii Regular
maintenance of
control valves
for combustion
at shell side
3.2.i Install
high
temperature
alarm,(TAH-432)
3.2.ii Regular
maintenance of
control valves
for combustion
at shell side
3.1.a Monitor
operating conditions
in furnace, F-101 &
102
and correct any
operating
abnormalities
3.2.a Monitor
in furnace, F-101
&102 and correct any
operating
abnormalities
S-44
Pressure
Less
1.1.
Low
Pressure
1.1.1. Abnormality
in RX-101 due to
significant pressure
drop
1.1.I. Production
rate
of RX-102 will
reduce
1.1.i. Install
pressure low
alarm (PAL-451)
1.1.ii. Regular
maintenance of
the pipelines
1.1.a. Check and

replace the rupture
pipeline
158 | A p p e n d i x
More
1.2.
High
Pressure
1.2.1. Blockage in
pipeline
1.2.2. Abnormality
in RX-101 operation
2.1.1. Abnormality
in RX-101
operation
2
Temperatu
re
Less
2.1.
Low
Temperature
2.1.2. Abnormality
in fuel combustion
operation at shell
side
1.2.I. Explosion
of RX1.2.II. 102 may
occur
due to high
volumetric
expansion
of
tubing side and
exposing with fuel
gases at shell side
2.1.I. Production
rate of RX-102 will
reduce
1.2.i. Install
pressure
high
alarm (PAH-441)
1.2.ii. Regular
maintenance
of the pipe lines
2.1.i. Install
low temperature
alarm,(TAL-442)
2.1.ii. Regular
maintenance of
control valves
for combustion
at shell side
1.2.a. Opening of
pressure relieve
valve (PRV-108)
1.2.b. Interlock
system
for reactor will
commence which
leads to partial
shutdown of reactor
section
2.1.a. Increasing
fuel and air input into
shell side for
combustion through
control valve, CV-133
& CV-134
159 | A p p e n d i x
More
2.2.
High
Temperature
2.2.1. Abnormality
in RX-101
operation
2.2.2. Abnormality
in fuel combustion
operation at shell
side
2.2.i. Install
high
temperature
alarm,(TAH-432)
2.2.I. Explosion
of RX-102 may
occur due to
thermal meltdown
of tubing side and 2.2.ii. Regular
exposing with fuel maintenance of
gases at shell side control valves
for combustion
at shell side
3.1.I. Loss of
feed into RX-102
No
3.1.
Flow
No
3.1.1. Pipe line

rupture
3.1.2. Abnormality
in RX-101
3.1.II. Overheatin
g of RX-101 that
may lead to
thermal meltdown
and explosion
Flow
Less
3.2.
flow
Less
3.2.1. Pipe line

partially blocked
3.2.2. Leakage of
the pipe line
3.2.I. Less feed

into RX-102
3.2.II. May not
achieve the
desired output for
RX- 102
3.1.i. Install
flow transmitter
(FT-431) to
indicate no flow
in stream S-41
3.1.ii.
3.1.iii. Regular
maintenance of
the pipelines
2.2.a. Reduce fuel

and air input into
shell side for
combustion through
& CV-134
2.2.b. Interlock
system for reactor
will commence which
leads to partial
shutdown of reactor
section
3.1.a. Open manual
valve, MV-109 so
that feed flow can
by-pass RX-101
3.1.b. Interlock
system for reactor
will commence which
leads to partial
shutdown of reactor
section
3.2.a. Monitor
3.2.i. Regular
Maintenance of in RX-101 and
the pipelines
correct any operating
abnormalities
160 | A p p e n d i x
More
3.3.
flow
More
3.1.1. Abnormality
in RX-101
Operation
3.1.2. Faulty MV109 that may lead
to overflow in S-44
3.3.I. Temperatur 3.3.i. Regular

e drop becomes
maintenance
more significant
of the pipelines
3.3.a. Monitor
in RX-102 and
abnormalities
3.3.b. Interlock
system for reactor
will commence which
leads to partial
shutdown of reactor
section
S-45
Less
1.1.
Low
Pressure
Press
ure
More
1.2.
More
Pressure
1.1.I. Desired
operating
pressure of S-45
cannot be
achieved
1.1.1. Abnormality
in RX-102 due to
significant pressure
drop
1.1.II. Compresso
r-101, C-101 has
to utilize more
energy
1.2.1. Blockage in
Pipeline
1.2.2. Abnormality
in RX-102
1.2.I. May cause

mechanical
failure in C-101
due to higher
inlet pressure
1.2.i. Install
pressure
low
alarm (PAL-451)
1.2.ii. Regular
maintenance
of the
pipelines
1.2.i. Install
pressure high
alarm (PAH-451)
1.2.ii. Regular
maintenance of
the pipe lines
1.1.a. Check and

replace the rupture
pipeline
1.2.a. Opening of
pressure relieve
valve (PRV-110)
161 | A p p e n d i x
Less
2.1.
Low
Tempera
ture
2.1.1. Abnormality
in RX-102 operation
2.1.2.
2.1.3. Abnormality
in fuel combustion
operation at shell
side
Temp
eratur
e
More
2.2.
High
Tempera
ture
2.2.1. Abnormality
in RX-102
operation
2.2.2. Abnormality
in fuel combustion
operation at shell
side
2.1.i. Install
low temperature
alarm,(TAL-442)
2.1.I. Negligible
consequences
2.1.ii. Regular
maintenance of
control valves
for combustion
at shell side
2.2.i. Install
high
temperature
alarm,(TAH442)
2.2.I. Explosion
of C- 101 may
occur due to
thermal meltdown
of tubing side and 2.2.ii. Regular
exposing with fuel maintenance
gases at shell side of
control
valves for
combustion at
shell side
2.1.a. Increasing
fuel and air input into
shell side for
combustion through
&CV-137
2.1.b. Interlock
system for reactor
will commence which
leads to partial
shutdown of reactor
section
2.2.a. Reduce fuel
and air input into
shell side for
combustion through
& CV-137
2.2.b. Interlock
system for reactor
will commence which
leads to partial
shutdown of reactor
section
162 | A p p e n d i x
No
3..
No Flow
3.1.. Pipe line

rupture
3.1.. Abnormality
in RX-102
3.2.1. Pipe line

partially blocked
Flow
Less
More
3..
Lesser
Flow
3..
More
Flow
3.2.2. Leakage of
the pipe line
3.2.3. Abnormality
in RX-102
3.3.1. Abnormality
in RX-101 operation
3.1.I. Overheatin
g of C-101 due to
no flow that may
cause
thermal
down and leading
to explosion
3.2.I. Overheatin
g of C-101 due to
lesser flow that
may cause
thermal down
and leading to
explosion
3.3.I. The
desired product
specification may
not be achieve
3.3.2. Faulty MV109 that may lead

3.3.II. Pipe
to overflow in S-44
rupture
3.1.a. Open manual

valve, MV-111 so
that feed flow can
by-pass RX-102
3.1.i. Regular
maintenance of
control
valves 3.1.b. Interlock
for
combustion system for reactor
at shell side
will commence which
leads to partial
shutdown of reactor
section
3.2.i. Regular
maintenance
of control valves
for
combustion
at shell side
3.3.i. Install
low temperature
alarm
3.2.a. Monitor
in RX-102 and
correct any
operating
abnormalities
3.3.a. Monitor
in RX-102 and
Abnormalities
3.3.b. Interlock
system for reactor
will commence which
leads
to
partial
shutdown of reactor
section
163 | A p p e n d i x
C-101, C-102 & C-103

Study Title: HAZOP
Drawing No.:
Part considered: C-101, 102, 103
Design intent: To generate electricity
Stream No.: S-47 S-49 S-51
No
1.1.
No flow
Flow
More
1.2.
More flow
Page: of
Date: 14.Apr.2016
Cause
1.1.1. Blockage
1.1.2. Burst
1.1.3. Large
leak
1.1.4. Incorrect
pressure
difference
1.2.1 High
temperature
1.2.2 High
pressure
1.2.3. Incorrect
pressure
difference
Consequence
Safeguards
Actions
1.1.IV. No flow to
subsequent part
1.1.V. Feed
lost/escape
1.1.i. Install flow

detector and alarm
1.1.ii. Regular
maintenance
1.1.d. Partial shutdown of the scrubber

1.1.e. Re-design for
the pressure
difference
1.1.f. Isolate the
faulty parts
1.2.I. High
pressure
1.2.II. More flow
to subsequent
part
1.2.i. Refer 1.1.i.

1.2.i. Refer 1.1.ii.

of control valve
164 | A p p e n d i x
Less
More
1.3.i. Refer 1.1.i.


parts
2.1.
Higher
pressure
1.1.1 Blockage
1.1.2 Higher
flowrate
1.1.3 Higher
temperatu
re
2.1.i. Install
pressure indicator
and alarm
2.1.ii. Install
automatic feed
controller
2.1.iii. Install
valves

control valve
relief valve
2.2.
Lower
pressure
2.2.1. Small
rupture
2.2.2. Minor leak 2.2.I. Reverse
2.2.3. Lower
flow
flowrate
2.2.II. Low flow
2.2.4. Lower
feed temperature
2.2.i. Refer 2.1.i.

2.2.a. Operate
pressure controller
3.1.i. Install
temperature
indicator and
alarm
3.1.a. Isolate
equipment failures
control valve
3.1.c. Emergency
shut-down
3.1.d. Provide more
cooling agent
1.3.
Less flow
2.1.I. More flow

to C-101, 102
or 103
2.1.II. Higher
temperature
Pressure
Less
1.3.II. Less flow

to subsequent
1.3.1. Partial
part
blockage
1.3.III.Low
1.3.2. Small
pressure
rupture
1.3.IV. Pressure
1.3.3. Minor leak
difference
changes
Temperatu
More
re
3.1.
Higher
Temperatu
re
3.1.1. Less
cooling agent
supplied
3.1.2. Higher
pressure
3.1.I. Overheati
ng of C-101,
102 or 103
3.1.II. Explosion
3.1.III.High
pressure
165 | A p p e n d i x
Stream No.: S-46 S-48 S-50 S-52
No
Flow
More
Less
Pressure
More
1.1.
No flow
1.2.
More flow
1.1.1. Blockage
1.1.2. Burst
1.1.3. Large
leak
1.1.4. Incorrect
pressure
difference
1.2.1. High
temperature
1.2.2. High
pressure
1.2.3Incorrect pr
essure difference
1.1.VI. No flow to
subsequent part
1.1.VII.
Fee
d lost/escape
1.1.iii. Install flow

detector and alarm
1.1.iv. Regular
maintenance
1.1.a Partial shutdown of the scrubber

1.1.b Re-design for
the pressure
difference
1.1.c Isolate the
faulty parts
1.2.I. High
pressure
1.2.II. More flow
to subsequent
part
1.2.i. Refer 1.2.i.

1.2.a Partial closure o

f control valve
1.3.i. Refer 1.1.i.


parts
2.1.i. Install
pressure indicator
and alarm
2.1.ii. Install
automatic feed
controller
2.1.iii. Install
valves

control valve
relief valve
1.3.
Less flow
1.3.I. Less flow

to subsequent
1.3.1. Partial
part
blockage
1.3.II. Low
1.3.2. Small
pressure
rupture
1.3.III.Pressure
1.3.3. Minor leak
difference
changes
2.1.
Higher
pressure
2.1.I. More flow

to adjacent
parts
2.1.II. Higher
temperature
2.1.III.Pipe
rupture
2.1.IV. Overheat
2.1.1 Blockage
2.1.2 Higher
flowrate
2.1.3 Higher
temperatu
re
166 | A p p e n d i x
Less
Temperatu
More
re
2.2.
Lower
pressure
3.1.
Higher
Temperat
ure
2.2.1. Small
rupture
2.2.2. Minor leak 2.2.III.Reverse
2.2.3. Lower
flow
flowrate
2.2.IV. Low flow
2.2.4. Lower
feed temperature
3.1.1. Less
cooling agent
supplied
3.1.2. Higher
pressure
3.1.I. Overheat
of C-101, 102
or 103
3.1.II. Explosion
3.1.III.High
pressure
2.2.i. Refer 2.1.i.

2.2.a Operate
pressure controller
3.1.i. Install
temperature
indicator and
alarm
3.1.a. Isolate
equipment failures
control valve
3.1.c. Emergency
shut-down
3.1.d. Provide more
cooling agent
167 | A p p e n d i x
FV-102
Study Title: HAZOP
Drawing No.:
Part considered: FV-102
Page: of
Date: 14.Apr.2016
Design intent: To flash hydrogen gas from products

Stream No.: S-54
No
1.1.
No flow
1.1.1. Line
rupture
Less
1.2.
Less flow
1.2.1 Pipe line part

ially blocked
More
1.3.
High flow
1.3.1. High
temperature
Flow
Consequence
Safeguards
1.1.I. No flow
to FV-102

alarm
1.1.ii. Regular
maintenance
1.2.I. Less
flow to FV102
1.2.II. Level
decreases in
FV-102
1.3.I. Pressure
increases in FV102
1.3.II. Overhea
t FV-102
1.3.III.Level
increases in FV102
Actions
1.1.a. Partial
shut-down
of the pretreatment
section.
1.2.i. Refer 1.1.i.

1.2.ii. Refer1.1.ii.
1.2.a. Refer 1.1.a..
1.3.i. Refer 1.1.i

1.3.a. Refer 1.1.a.
168 | A p p e n d i x

valve
2.1.b. Open control
valve
2.2.a. Check and
replace the
leakage part
2.2.b. Partial close of
control valve
More
2.1.
High
pressure
2.1.1. Blockage in
pipe line
Less
2.2.
Low
pressure
2.2.1. Fouling
2.2.2. Leakage
from the pipe line
2.2.I.
Reverse flow

2.2.ii. Refer 2.1.i.
2.2.iii. Refer 2.1.ii.
3.1.
High
Temperature
3.1.1. Temperature
of cooling water
is hotter than
usual
3.1.I. More
flow to FV102
3.1.II. Overhea
t FV-102
3.1.i. Install
temperature
sensitive alarm
3.1.a. Increase
cooling water
flowrate
3.2.1. Temperature
of cooling water
is cooler than
usual
3.2.I. Low flow

3.2.II. Low
pressure
3.2.i. Refer3.1.i
3.2.a. Decrease
cooling water
flowrate
1.1.1. Line
rupture
1.4.I. No flow
to subsequent
part

alarm
1.4.ii. Regular
maintenance
1.5.1. Pipe line

partially blocked
1.5.I. Less
flow to
subsequent part
1.5.II. Level
increases in FV102
1.5.i. Refer 1.1.i.

indicator and alarm
1.5.a. Refer 1.1.a.

1.5.b. Open control
valve
Pressure
More
3
2.1.I.
Pipe rupture
2.1.i. Regular
maintenance of
the pipe lines
2.1.ii. Install
pressure detector and
alarm
Tempera
ture
Less
3.2.
Low
Temperature
Stream No.: S-55

No
1
1.1.
No flow
Flow
Less
1.2.
Less flow
169 | A p p e n d i x
More
More
1.3.
High flow
1.6.1. Leakage
1.6.2. Low
pressure
2.1.
High
pressure
2.3.1. Blockage in
pipe line
2.3.2. High
temperature
2.3.3. High flow
2.2.
Low
pressure
2.2.1. Fouling
2.2.2. Leakage
2.2.3. Low flow
2.2.4. Low
temperature
Pressure
Less
1.6.I. Level in
FV-102
decreases
1.6.II. More
flow to
subsequent part
2.3.I. Level
decreases in
FV-102
2.3.II. More
flow
2.3.III.Higher
temperature
2.2.I. Reverse
flow
2.2.II. Level
increases in FV102
2.2.III.Lower
temperature
1.6.i. Refer1.1.i.
1.6.iii. Refer 1.2.iii
1.6.a. Refer 1.1.a.

valve
2.1.i. Regular
maintenance of the
pipe lines
2.1.ii. Install
alarm

valve
2.1.b. Open control
valve

2.2.a. Check and

replace the leakage
part
control valve

alarm
1.4.ii. Regular
maintenance
1.5.i. Refer 1.1.i.

indicator and alarm
1.5.a. Refer 1.1.a.

1.5.b. Open control
valve
Stream No.: S-89
No
1.4.
No flow
1.4.1. Line
rupture
Less
1.5.
Less flow
1.5.1. Pipe line

partially blocked
Flow
1.4.I. No flow
to
subsequent
part
1.5.I. Less
flow to
subsequent
part
1.5.II. Pressure
builds up in FV102
170 | A p p e n d i x
1.6.
High flow
1.6.1. Leakage
1.6.2. Low
pressure
1.6.I. Pressure
in FV-102
decreases
1.6.II. More
flow to
subsequent part
More
2.1.
High
pressure
2.1.1. Blockage in
pipe line
2.1.2. High
temperature
2.1.3. High flow
2.1.I. Pressure
builds up in
FV-102
2.1.II. Higher
temperature
2.1.iii. Regular
maintenance of the
pipe lines
2.1.iv. Install
alarm

valve
2.1.b. Open control
valve
Less
2.2.
Low
pressure
2.2.1. Fouling
2.2.2. Leakage
2.2.3. Low flow
2.2.4. Low
temperature
2.2.I. Reverse
flow
2.2.II. Lower
temperature

2.2.a. Check and

replace the
leakage part
control valve
More
Pressure
1.6.i. Refer1.1.i.
1.6.iii. Refer 1.2.iii
1.6.a. Refer 1.1.a.

valve
171 | A p p e n d i x
PSA-101
Study Title: HAZOP for
Drawing No.:
Part considered: PSA-101
Page: of
Date: 14.Apr.2016
Design intent: To utilize hydrogen gas

Stream No.: S-89: Refer to FV-102
Cause
Consequence
Safeguards
Actions
No
1.1.
No flow
1.1.2. Line
rupture
1.1.II. No
purge gas
1.1.III.Pressure
builds up in
PSA-101
1.1.iii. Install low flow

alarm
Regular maintenance
Less
1.2.
Less flow
2.
Pipe line
partially
blocked
1.2.III.Less
purge gas
1.2.iii. Regular
maintenance
1.2.iii. Install low flow
alarm
No
1.1.
flow
1.1.1. Line
rupture
1.1.I. H2 lost
1.1.II. Ignition
Less
1.2.
Le
ss flow
1.2.1. Pipe line

partially
blocked
1.2.I. Ignition
1.2.II. He less
collected
Flow
Stream No.: S-91
Flow
No

alarm
Regular maintenance
1.2.i. Regular
maintenance
1.2.iv. Install low flow
alarm

172 | A p p e n d i x
CR-101
Study Title: HAZOP for
Drawing No.:
Part considered: CR-101
Page: of
Date: 14.Apr.2016
Design intent: To crystalize naphthalene

Stream No.: S-87
No
Less
1
Flow
More
Pressure
More
Cause
Consequence
Safeguards
1.1.
No flow
1.1.1. Line
rupture
1.1.I. No flow
to CR-101

alarm
1.1.ii. Regular
maintenance
1.1.a. Partial shutdown of the pretreatment

section.
1.2.
Less flow
1.2.1. Pipe line

partially
blocked
1.2.i. Refer 1.1.i.

1.2.a. Refer 1.1.a..
1.3.
High flow
1.3.1. High
temperature
1.2.I. Less
flow to CR101
1.3.I. Pressure
increases in
CR-101
1.3.II. Overhea
t
CR-101
2.1.
High
pressure
2.1.1. Blockage
in pipe line
2.1.I.
Pipe rupture
Actions
1.3.i. Refer 1.1.i

1.3.a. Refer 1.1.a.
2.1.i. Regular
maintenance of
the pipe lines
2.1.ii. Install
alarm

valve
2.1.b. Open control
valve
173 | A p p e n d i x
Less
2.2.
Low
pressure
More
3.1.
High
Temperat
ure
Less
3.2.
Low
Temperat
ure
Temperatu
re
2.2.1. Fouling
2.2.2. Leakage
from the pipe
line
3.1.1. Tempera
ture of
cooling
water is
hotter than
usual
3.2.1. Tempera
ture of
cooling
water is
cooler than
usual
2.2.I.
Reverse flow

2.2.a. Check and

replace the
leakage part
control valve
3.1.I. More
flow to CR101
3.1.II. Overhea
t CR-101
3.1.i. Install
temperature
sensitive alarm
3.1.a. Increase
cooling water
flowrate
3.2.I. Low flow

3.2.II. Low
pressure
3.2.i. Refer3.1.i
3.2.a. Decrease
cooling water
flowrate
1.1.I. No
naphthalene
stored

alarm
1.1.ii. Regular
maintenance
1.1.a. Partial shutdown of the pretreatment

section.
1.2.i. Refer 1.1.i.

1.2.a. Refer 1.1.a..
Stream No.: S-88
Flow
No
1.1.1. Line
rupture
1.1.2. Heavy
blockage
1.1.3. Large
leakage
No
1.1.
flow
Less
1.2.
Le
ss flow
1.2.1. Blockage
1.2.2. Leakage
More
1.3.
Hi
gh flow
1.3.1. High
temperature
1.2.I. Some
naphthalene
lost
1.3.I. Pressure
increases in
stored
1.3.i. Refer 1.1.i

1.3.a. Refer 1.1.a.
174 | A p p e n d i x
2.1.I. Pipe
rupture
2.1.II. High
temperature
2.1.III.Ignition
of flammable
naphthalene
2.1.IV. Explosio
n
2.1.i. Regular
maintenance of the
pipe lines
2.1.ii. Install
alarm
More
2.1.
High
pressure
2.1.1. Blockage
in pipe line
Less
2.2.
Low
pressure
2.2.1. Fouling
2.2.2. Leakage
from the pipe
line
2.2.I. Reverse
flow

3.1.
High
Temperat
ure
3.1.1. Tempera
ture of cooling
water is hotter
than usual
3.1.I. Refer
2.1.III.
3.1.II. Refer
2.1.IV.
3.1.i. Install
alarm
Pressure
Temperatu
More
re

valve
2.1.b. Open control
valve
2.2.a. Check and

replace the leakage
part
control valve
3.1.a. Partial shutdown of CR-101
3.1.b. Open CV-166
3.1.c. Provide more
coolant
175 | A p p e n d i x
DC-102
Study Title: HAZOP
Drawing No.:
HAZOP Team: Fidelia
Page: of
Date: 14.Apr.2016
Design intent: To first distillate benzene

Stream No.: S-59
Consequence
Safeguards
Actions
1.1.i Install low flow

alarm
No
Flow
Less
1.1.I
Loss
of
No 1.1.1 Pipe line
feed into DC-102
rupture
1.1.ii
Regular
maintenance of the
pipelines
1.2.1 Pipe line 1.2.I Less feed
1.2.i Install low flow
partially
into DC-102
alarm
blocked
1.2 Less
1.2.2 May not
1.2.ii
Regular
Flow
1.2.2 Leakage achieve
the
maintenance of the
of the pipe line
desired
output
pipelines
for DC-102
1.1
Flow
1.1.a Partial shutdown of the pretreatment section
1.2.a Partial shutdown of the pretreatment section
1.3.i Install high flow

alarm
More
Pressure
Less
1.3.1
High
1.3 More
1.3.I Flooding in
pressure due to
Flow
DC-102
1.3.ii
valve failure
maintenance
pipelines
2.1.1
Fouling 2.1.I
Reverse
2.1 Low
2.1.i Install
leakage
from flow from DCPressure
return valve
the pipeline
102
1.3.a Partial shutdown of the preRegular

treatment section
of the
non-
2.1.a
Check
and
replace the leakage
part
176 | A p p e n d i x
More
Less
Temperatu
re
More
2.2 High
Pressure
2.2.1 Blockage 2.2.I

in pipeline
rupture
2.2.2
Valve
failure
3.1.1
Temperature of
3.1 Low
the stream is
Temperat
lower
than
ure
usual due to
valve failure
3.2.1
Temperature of
3.2 High
the stream is
Temperat
higher
than
ure
usual due to
valve failure
Pipe
2.2.i
maintenance
pipe lines
Regular
2.2.a
of the
valve
3.1.i
Install
low
3.1.I The desired
temperature alarm
product
specification
3.1.ii
Regular
may
not
be
maintenance of the
achieve
valve
3.2.i
Install
high
3.2.I The desired temperature alarm
product
specification
may
not
be 3.2.ii
Regular
achieve
maintenance of the
valve
Open
relieve
3.1.a
Check
and
replace the valve
3.2.a
Check
and
replace the valve
S-60
Less
1
Pressure
More
1.1.i Install low alarm

1.1.I The desired
1.1.1
Lower
pressure
product
1.1 Low pressure
specification
Pressure supplied
from
1.1.ii
Regular
may
not
be
the inlet
maintenance
of
achieve
reboiler
1.2.i Install high alarm
1.2.I The desired
1.2.1
Higher
pressure
product
1.2 High pressure
specification
Pressure supplied
from
1.2.ii
Regular
may
not
be
the inlet
maintenance
of
achieve
reboiler
1.1.a
Check
and
replace the leakage
part
1.2.a
valve
Open
relieve
177 | A p p e n d i x
Less
2
Temperatu
re
More
Less
3
Flow
More
2.1.1
Lower
temperature
2.1.I The desired
supplied
from
2.1 Low
product
the inlet
Temperat
specification
ure
may
not
be
2.1.2 Low level
achieve
inside
the
reboiler

temperature
2.1.ii
maintenance
valve
2.1.a Increase
Regular reboiler duty
of the
the

2.2.I The desired
2.2.1
Higher
temperature
2.2 High
product
temperature
2.2.a Decrease the
Temperat
specification
supplied
from
2.2.ii
Regular reboiler duty
ure
may
not
be
the inlet
maintenance
of
achieve
reboiler
3.1.a Partial shut3.1.I The desired
down of the pre3.1.1
Lesser product
3.1 Less
3.1.i Install low flow treatment section
flow
supplied specification
flow
alarm
from the inlet
may
not
be
3.1.b Decrease the
achieve
feed flow
3.2.a Partial shut3.2.I The desired
down of the pre3.2.1 More flow product
3.2 More
3.2.i Install high flow treatment section
supplied
from specification
flow
alarm
the inlet
may
not
be
3.2.b Increase the
achieve
feed flow
S-61
178 | A p p e n d i x
Less
Pressure
More
Less
2
Temperatu
re
More
1.1.1
Lower
pressure
1.1.I The desired
supplied
from product
1.1 Low
the inlet
specification
Pressure
may
not
be
1.1.2 Reboiler achieve
Leakage
1.2.I The desired
product
specification
1.2.1
High
may
not
be
1.2 High pressure
achieve
Pressure supplied
from
the inlet
1.2.II Less flow
that goes back
to the column

pressure
1.1.ii
maintenance
reboiler
1.1.a
Check
and
replace the leakage
Regular
part
of

pressure
1.2.ii
maintenance
reboiler
Regular
of
2.1.i
Install
low
2.1.I The desired
2.1.1
Lower
temperature alarm
2.1 Low
product
temperature
Temperat
specification
supplied
from
2.1.ii
Regular
ure
may
not
be
the reboiler
maintenance
of
achieve
reboiler
2.2.i
Install
high
2.2.I The desired
2.2.1
Higher
temperature alarm
2.2 High
product
temperature
Temperat
specification
from
the
2.2.ii
Regular
ure
may
not
be
reboiler
maintenance
of
achieve
reboiler
1.2.a Decrease the

reboiler pressure
2.1.a Decrease the

reboiler temperature
2.2.a
Increase
temperature of the
reboiler
S-67
179 | A p p e n d i x
Less
1
1.1.I The desired

product
specification
1.1.1
Less
1.1 Low
may
not
be 1.1.i
Install
pressure from
Pressure
achieve
pressure alarm
the reboiler
Pressure
More
1.2.1
High
1.2 High
pressure from
Pressure
the reboiler
Less
2.1.1
Low
2.1 Low
temperature
Temperat
from
the
ure
reboiler
Temperatu
re
More
1.1.II
Pipe
rupture
1.2.I The desired
product
specification
may
not
be
achieve
2.1.I The desired
product
specification
may
not
be
achieve
1.2.i
Install
pressure alarm
low
high
1.1.a Increase
pressure
of
reboiler
the
the
1.2.a Decrease the

pressure
of
the
reboiler
2.1.a Increase
2.1.i
Install
low
temperature
temperature alarm
reboiler
2.1.II
Pipe
rupture
2.2.I The desired
2.2.1
High
2.2 High
product
2.2.a Decrease
temperature
2.2.i
Install
high
Temperat
specification
temperature
from
the
temperature alarm
ure
may
not
be
reboiler
reboiler
achieve
the
of
the
of
S-62
1
Pressure
Less
1.1.1
Lower
1.1 Low pressure
Pressure supplied
from
the column.
1.1.I The desired

specification
1.1.i
Install
may
not
be pressure alarm
achieved
low
1.1.a Increase the

operating
pressure
of the column
180 | A p p e n d i x
More
1.2 High
Pressure
Less
2.1 Low
Temperat
ure
More
2.2 High
Temperat
ure
Less
3.1 Less
Flow
Temperatu
re
Flow
More
1.2.1
Higher
pressure
supplied
from
the column.
2.1.1
Lower
temperature
from
the
column
2.2.1
Higher
temperature
from
the
column
3.1.1
Lower
flow come out
from
the
column
1.2.I The desired

specification
may
not
be
achieved
2.1.I The desired
specification
may
not
be
achieved
2.2.I The desired
specification
may
not
be
achieved
3.1.I The desired
specification
may
not
be
achieved
3.2.I
Flooding
can be occurred
1.2.i
Install
pressure alarm
high
1.2.a Decrease the

operating pressure of
the column
2.1.a Increase the

2.1.i
Install
low operating
temperature alarm
temperature of the
column
2.2.a Decrease the
2.2.i
Install
high operating
temperature alarm
temperature of the
column
3.3.i Install low flow 3.3.a Increase the
alarm
feed to the column
3.2.1
Higher
3.2 More flow come out 3.2.II
The 3.2.i Install high flow 3.2.a Decrease the
Flow
from
the desired
alarm
feed to the column
column
specification
may
not
be
achieved.
S-63
1
Pressure
Less
1.1.I The desired

1.1.1
Lower
product
1.1 Low pressure
1.1.i
Install
specification
Pressure supplied
from
pressure alarm
may
not
be
the condenser
achieve
1.1.a
Increase
pressure
of
the
low
condenser
Regular maintenance
of the condenser
181 | A p p e n d i x
More
Less
2
Temperatu
re
More
1.2.I The desired

product
1.2.1
Higher specification
1.2 High pressure
may
not
be 1.2.i
Install
high
Pressure supplied
from achieve
pressure alarm
the condenser
1.2.II
Pipe
rupture
2.1.I The desired
product
2.1.1
Higher specification
2.1 Low
temperature
may
not
be 2.1.i
Install
low
Temperat
supplied
from achieve
temperature alarm
ure
the condenser
2.1.I
Pipe
rupture
2.2.I The desired
2.2.1
Lower
2.2 High
product
temperature
2.2.i
Install
high
Temperat
specification
supplied
from
temperature alarm
ure
may
not
be
the condenser
achieve
1.2.a
pressure
condenser
Decrease
of
the
1.2.b
Regular
maintenance of the
condenser
2.1.a
Increase
temperature of the
condenser
2.1.b
Regular
maintenance of the
condenser
2.2.a
Decrease
temperature of the
condenser
S-64
More
1.1.1 Less feed

1.1 Low
from S-63 to
level
the reflux drum
Less
1.2.1 More feed

1.2 High
from S-63 to
level
the reflux drum
Level
1.1.I The desired

product
specification
may
not
be
achieve
1.2.I The desired
product
specification
may
not
be
achieve
1.1.a
Check
and
1.1.i Install high level
regular maintenance
alarm
of reflux drum
1.2.a
Check
and
1.2.i Install low level
regular maintenance
alarm
of reflux drum
182 | A p p e n d i x
More
2
Temperatu
re
Less
More
3
Pressure
Less
2.1.I The desired

2.1.1
Less
2.1 Low
product
temperature
Temperat
specification
provided from
ure
may
not
be
the reflux drum
achieve
2.2.1
High
2.2.I The desired
temperature
2.2 High
product
provided from
Temperat
specification
the
reflux
ure
may
not
be
drum.
achieve
2.1.a
Decrease
2.1.i
Install
high
temperature of the
temperature alarm
reflux drum
2.2.a
Increase
2.2.i
Install
low
temperature of the
temperature alarm
reflux drum
3.1.I The desired

product
3.1.1
High
specification
pressure
3.1 High
may
not
be 3.1.i
Install
supplied
from
Pressure
achieve
pressure alarm
the
reflux
drum.
3.1.II
Pipe
rupture
3.2.1
Low 3.2.I The desired
pressure
product
3.2 Low
3.2.i
Install
supplied
from specification
Pressure
pressure alarm
the
reflux may
not
be
drum.
achieve
high
low
3.1.a Decrease the

pressure of the reflux
drum
3.2.a Increase the

pressure of the reflux
drum
S-65
1
Pressure
Less
1.1.I The desired

1.1.1 Pump is product
1.1 Low
1.1.i
Install
not
function specification
Pressure
pressure alarm
properly
may
not
be
achieve
low
1.1.a
Regular
maintenance of the
pump
183 | A p p e n d i x
Flow
Less
2.1.I The desired

2.1.1 Pump is product
2.1 Less
2.1.i
Install
not
function specification
flow
pressure alarm
properly
may
not
be
achieve
low
2.1.a
Regular
maintenance of the
pump
S-66
Less
1
Pressure
More
1.1.I The desired

1.1.1
Low
product
1.1 Low pressure
specification
Pressure supplied
from
may
not
be
the reflux drum
achieve
1.2.I The desired
1.2.1
High
product
1.2 High pressure
specification
Pressure supplied
from
may
not
be
the reflux drum
achieve
1.1.i
Install
pressure alarm
1.2.i
Install
pressure alarm
low
1.1.a
Check
and
replace the leakage
part
high 1.2.a
valve
Open
relief
184 | A p p e n d i x
DC-103
Study Title: HAZOP
Drawing No.:
HAZOP Team: Elaine Soh
Page: of
Date: 14.Apr.2016
Design intent: To second distillate benzene

S-68 and S-67
More
Safeguards
Actions
1.1
More
flow
1.1.1 High liquid

level in reboiler
DC-102.
1.1.2 Failure in
reboiler control
valve
1.1.I
Affects
separation
in
distillation
column
if
beyond
the
limit.
1.1.II Flooding
of column.
1.1.III
High
pressure
in
column.
1.2
Less flow
1.2.1
Pipe
blockage
and
leakage
1.2.2
Reboiler
failure
1.2.3
Utility
temperature too
high
1.2.4 Failure in
reboiler control
valve
1.2.I Pressure
1.2.a Use detector to
builds
up
in
detect leakage or
pipe, resulting
blockage in pipe.
in pipe rupture 1.2.i
Temperature 1.2.b
Decrease
and explosion.
indicator.
steam flow to RE1.2.II
Fewer 1.2.ii Flow indicator.
103.
products.
1.2.c. Change
1.2.III
Larger
reboiler control valve
vapour
flow
manual mode and
back to DC-102.
open control valve.
Flow
Less
Consequence
1.1.i
Install
indicator.
1.1.a Close control

valve partially.
flow
1.1.b
Increase
steam flow to RE103.
185 | A p p e n d i x
Reverse
No
Temperatu
re
More
1.3
Reverse
flow
1.4
No flow
1.3.1
Malfunction of
throttling
valve(V-132)
1.3.I
Damage
reboiler.
to
1.3.i Install
valve.
1.4.I Release of
hydrocarbon to
surrounding.
1.4.1
Pipe 1.4.II Fire and
rupture.
explosion
if
1.4.i
Install
1.4.2 Failure in ignition source
indicator.
bottom control is present.
valve of DC-102. 1.4.III Pressure
build-up in RE103.
2.1.1 Failure of
steam
controlling valve
in DC-102.
2.1.2
Higher
steam
2.1 High
temperature to
feed
reboiler in DCtemperat
102.
ure
2.1.3
Malfunction
of
throttling valve
causing
high
pressure feed.
2.1.I
Higher
vapour flow in
DC-103.
2.1.II
Entrainment
and flooding in
DC-103.
2.1.III Level in
reflux
drums
increases.
1.3.a Close valve in

by-pass current
line
and
switch to by-pass
line.
1.4.a Check bottom
control valve of DC102.
flow
1.4.b
Emergency
shut
down
and
evacuation
if
needed.
2.1.i
Temperature
indicator
2.1.ii Flow indicator
2.1.iv. Install level
alarm.
2.1.a
Decrease
steam
flow
to
reboiler in DC-102.
2.1.b Close valve in
current
line
and
switch to by-pass
line.
186 | A p p e n d i x
Pressure
Less
2.2.1 Failure of
steam
controlling valve
in DC-102.
2.2.2
Lower
2.2 Low steam
feed
temperature to
temperat reboiler in DCure
102.
2.2.3
Malfunction
of
throttling valve
causing
low
pressure feed.
More
3.1.I Liquid will

not flow down
and
causes
entrainment.
3.1.II Flooding
3.1.1 Throttling in the rectifying
3.1 High valve failure.
stage.
feed
3.1.2
Pipe 3.1.III
Higher
pressure blockage due to pressure
in
fouling
column.
3.1.IV
Pipe
rupture
and
emission
of
hydrocarbon to
surrounding.
2.2.I High liquid

flow in DC-103.
2.2.II Weeping
occur in DC103.
2.2.III.Level in
reflux drums
decreases.
2.2.i
Temperature
indicator.
2.2.ii Install by-pass
valve.
2.2.iii
Install
level
controller
and
level
alarm.
3.1.i
controller.
3.1.ii Install
alarm.
3.1.iii Install
relief valve.
3.1.ivInstall
valve.
2.2.a
Increase
steam
flow
to
reboiler in DC-102.
2.2.b Close valve in
current
line
and
switch to by-pass
line.
Pressure
3.1.a Open by-pass

valve.
pressure
3.1.b Open pressure
relief valve.
pressure
3.1.c
Emergency
shut
down
and
by-pass
evacuation.
187 | A p p e n d i x
Less
3.2.i
Pressure
3.2.I Backflow controller.
3.2.a Open by-pass
3.2.1 Throttling
3.2 Low
of feed.
3.2.ii Install pressure valve.
valve failure.
feed
3.2.II
Release alarm.
3.2.b.
Emergency
3.2.2
Pipe
pressure
of hydrocarbon 3.2.iii Install by-pass shut
down
and
leakage.
to environment. valve.
evacuation.
S-69
Flow
More
Less
1.1
More
flow
1.1.1
Low
temperature in
column
1.1.2
Low
cooling
water
temperature
1.1.3 Low steam
temperature
1.2.1
High
temperature in
column
1.2.2
High
1.2 Less cooling
water
flow
temperature
1.2.3
High
steam
temperature
1.1.I High liquid

level in reboiler
DC-102.
1.1.II
Higher
bottom product
flow
1.1.III
Higher
flowrate of S-70
1.2.I
Lower
liquid level in
reboiler
1.2.II.
Lower
bottom product
flow.
1.2.III.
Lower
flowrate of S70.
1.1.a Open bottom

product
control
1.1.i
Install
valve.
flow to RE-104.
1.2.a
Reduce
opening of bottom
product
control
1.2.i
Install
valve.
1.2.b
Decrease
188 | A p p e n d i x
No
1.3
flow
1.3.I Release of
hydrocarbon to
surrounding.
1.3.1 No feed to
1.3.II Result in
No DC-103
fire if ignition 1.3.i
Install
1.3.2
Pipeline
source
is indicator
rupture
present.
1.3.III
Explosion
flow
1.3.a Unlikely.
S-70
Flow
More
1.1.1
High
steam flow to
reboiler
1.1 More
1.1.2
High
flow
steam
temperature
1.1.3 High flow
of S-69
1.1.I
Higher
vapour flow in
stripping
region.
1.1.II
Might
affect
separation
in
column
1.1.III
Might
result
in
entrainment or
flooding
1.1.i.
Install
1.1.a. Reduce steam
1.1.ii
Install
flow flow to RE-104.
indicator
189 | A p p e n d i x
Less
Temperatu
re
More
Less
1.2.I
Lower
vapour flow in
1.2.1 Low steam
stripping
flow to reboiler
1.2 Less
region.
1.2.2 Low steam
flow
1.2.II
Might
temperature
affect
1.2.3 Low flow
separation
in
of S-69
column
2.1.I
High
column
temperature
2.1.II
Higher
vapour flow in
column.
2.1.III
Might
affect
separation
in
column
2.1
Higher
temperat
ure
2.1.1
High
steam flow to
reboiler
2.1.2
High
steam
temperature
2.1.3 Failure in
steam
controlling valve
2.2
Lower
temperat
ure
2.2.I
Low
column
2.2.1 Low steam
temperature
flow to reboiler
2.2.II
Lower
2.2.2 Low steam
vapour flow in
temperature
column.
2.2.3 Failure in
2.2.III
Might
steam
affect
controlling valve
separation
in
column
1.2.i
Install
1.2.ii
Install
flow flow to RE-104.
indicator
2.1.i
Install
2.1.a Reduce steam
2.1.ii
Install
flow to RE-104.
temperature
alarm
high (TAH)
2.2.i
Install
2.2.ii
Install
flow to RE-104.
temperature alarm low
(TAL)
S-71 and S-72

190 | A p p e n d i x
Flow
More
Less
Temperatu
re
Pressure
Less
Less
1.1.i
Install
1.1.1
Column 1.1.I High level temperature indicator.
1.1 More high
in reflux drum.
1.1.ii
Install
flow
temperature
1.1.II
More temperature
alarm
distillate flow.
high (TAH).
1.1.a
Increase
cooling water flow to
C0-104.
1.1.b Reduce steam
flow to RE-104.
1.2.i
Install
1.2.ii
Install
(TAL).
1.2.a
Decrease
C0-104.
flow to RE-104.
2.1.i
Install
indicator.
2.1.iii
Install
(TAL).
2.1.a
Decrease
C0-104.
flow to RE-104.
3.1.i Install pressure

3.1.1
Column
indicator.
3.1 Low low temperature 3.1.I Lower flow
pressure 3.1.2
Low in S-71
alarm low (TAL).
vapour flow
3.1.a
Decrease
C0-104.
flow to RE-104.
1.2.I Low level

1.2.1
Column
1.2 Less
in reflux drum.
low temperature
flow
1.2.II
Less
distillate flow.
2.1.I
Reflux
flow
lower
2.1.1
Column
2.1 Low
temperature.
low temperature
temperat
2.1.II Decrease
2.1.2
Steam
ure
pressure
of
valve failure
column.
S-73 and S-74
191 | A p p e n d i x
Flow
More
Less
Temperatu
re
Less
1.1.1 More flow

in S-71
1.1.2
Low
cooling
water
1.1 More
temperature
flow
1.1.3
High
cooling
water
flowrate
1.2.1 Less flow
in S-71
1.2.2
High
cooling
water
1.2 Low
temperature
flow
1.2.3
Low
cooling
water
flowrate
2.1 Low
temperat
ure
2.1.1
Low
cooling
water
temperature
2.1.2
Low
cooling
water
flowrate
2.1.3
Cooling
water
valve
failure
1.1.I
Higher
reflux flow to
column.
1.1.II
Might
affect
1.1.i
Install
separation
in indicator.
column.
1.1.III Increase
in pump duty of
P-107.
1.1.a
Decrease
cooling water flow.
flow
1.1.b
Decrease
1.2.I
Lower
reflux flow to
column.
1.2.II
Might 1.2.i
Install
affect
indicator.
separation
in
column.
1.2.a.
Increase
flow steam flow to RE104.
2.1.I
Cooler
reflux flow back
to column.
2.1.II Decrease
in
column
2.1.a
Decrease
2.1.i
Install
temperature
2.1.III
Might
CO-104
affect
separation
in
column.
S-75
192 | A p p e n d i x
Flow
More
Less
1.1.1 High level

in reflux drum
1.1.2 High
1.1 More temperature of
flow
column
1.1.3 Pump (P107) failure
1.2.1 Low level

in reflux drum.
1.2.2 Low
temperature of
1.2 Less column
flow
1.2.2 Pipeline
leakage
1.2.3 Low feed
flowrate
1.1.I Higher
flowrate of
distillate.
1.1.II Overflow
in storage tank.
1.1.III No reflux
flow back to
column.
1.2.I Lower
flowrate of
distillate.
1.1.i Install flow

indicator.
1.1.ii Install level
indicator at storage
tank.
1.1.iii Install level
alarm high (LAH) at
storage tank.
1.1.ii Install back-up
pump
1.1.ii Regular
maintenance on pump
1.2.i Install flow

indicator.
1.2.ii Regular
maintenance.
1.1.a Check
temperature of
column.
flow to reboiler.
of pump.
1.2.a Check
temperature of
column.
flow to reboiler.
of pipelines.
193 | A p p e n d i x
Temperatu
re
More
2.1 High
temperat
ure
2.1.1 Cooling
water valve
failure
2.1.2 Condenser
failure
2.1.I High
temperature of
benzene to
storage.
2.1.II
Formation of
benzene vapour
in storage tank.
2.1.III High
pressure in
storage tank.
2.1.i Install
2.1.ii Install
temperature alarm
2.1.iii Install pressure
alarm high (PAH) to
storage tank.

water flow.
2.1.b Check condition
of condenser
S-77
Flow
More
1.1.1 Low
temperature and
pressure in
column
1.1 More 1.1.2 Steam
flow
valve failure
1.1.3 Higher
feed flowrate
1.1.4 Reboiler
failure
1.1.i Install
temperature and
1.1.I Increase
pressure indicator to
feed to DC-104.
DC-103.
1.1.II Decrease
1.1.ii Regular
in distillate flow.
maintenance on
reboiler.
1.1.a Check
temperature and
pressure of column.
1.1.b Check feed
flowrate
1.1.c Increase steam
flow to RE-103.
condition
194 | A p p e n d i x
Less
Temperatu
re
Less
1.2.1 High
temperature and
pressure in
column
1.2 Less 1.2.2 Steam
flow
valve failure
1.2.3 Lower feed
flowrate
1.2.4 Reboiler
failure
2.1
Lower
temperat
ure
2.1.1 Steam
valve failure
2.1.2 Reboiler
failure
1.2.I Decrease
feed to DC-104.
1.2.II Increase
in distillate flow.
1.2.i Install
temperature and
pressure indicator to
DC-103.
1.2.ii Regular
maintenance on
reboiler.
2.1.I Higher
feed
temperature to
DC-104.
2.1.II Affects
separation in
DC-104
2.1.i Install
2.1.ii Install
temperature alarm.
2.1.iii Regular
maintenance on
reboiler.
1.2.a Check
temperature and
pressure of column.
flow to RE-103.
1.2.c Check feed
flowrate
condition

flowrate.
2.1.b Check reboiler
condition
195 | A p p e n d i x
DC-104
Study Title: HAZOP
Drawing No.:
Page: of
Date: 14.Apr.2016
Design intent: To distillate phenol

Stream No.: S-77
More
1.1. High
Flow
Less
1.2. Low
Flow
Flow
No
Pressure
More
1.3. No
flow
2.1. High
pressure
Cause
Consequence
Safeguards
Actions
1.1.1. High
temperature
1.1.2. High
pressure
1.2.1 Low
temperature
1.2.2. Low
pressure
1.2.3. Leakage
1.2.4. Blockage
1.3.1. Large
blockage
1.3.2. Large
leakage
1.3.3. Line
rupture
1.1.I. More feed

to DC-104
1.1.II. Pressure
increases
1.1.i. Install feed

indicator and alarm
1.1.ii. Regular
maintenance
1.1.a Close control

valve
1.2.I. Less feed

to DC-104
1.2.i. Refer 1.1.i.

1.2.a Open control

valve
1.3.I. No feed
to DC-103
1.3.II.
Distillation
failure
1.3.i. Refer 1.1.i

1.3.a Replace the

faulty parts
2.1.I. Pressure
load in DC-104
increases
2.1.II.
Overpressure
2.1.III.
Explosion
2.1.i. Install pressure

detector and alarm
2.1.ii. Regular
maintenance
2.1.a Open control

valve
2.1.1. Blockage
2.1.2. High flow
196 | A p p e n d i x
Less
2.2 Low
pressure
2.2.1. Rupture
2.2.2. Leakage
2.2.3. Low flow
2.2.I. Pressure
difference
changes
2.2.II.
Distillation
failure
2.2.i. Refer 2.1.i.

2.2.a Close control

valve
1.1.I. No feed
flow
1.1.II Gas lost
1.1.i. Install feed

indicator and alarm
1.1.ii. Regular
maintenance
1.1.a Replace the

faulty parts
1.1.b. Temporary
shut-down of DC-104
1.2.I. Less feed

flow to
subsequent part
1.2.i. Refer 1.1.i.

1.2.a Open control

valve
2.1.I. Line
rupture
2.1.II. Pressure
difference
changes
2.1.i. Install pressure

detector and alarm
2.1.a. Open control

valve
2.2.I. Reverse
flow
2.2.i. Refer to 2.1.i.

valve
Stream No.: S-78
No
1.1. No
flow
Less
1.2. Low
Flow
Flow
1.1.1. Large
blockage
1.1.2. Large
leakage
1.1.3. Line
rupture
1.2.1 Low
temperature
1.2.2. Low
pressure
1.2.3. Leakage
1.2.4. Blockage
More
2.1. High
pressure
2.1.1. Blockage
2.1.2. High
temperature
2.1.3. High flow
Less
2.2. Low
pressure
2.2.1. Leakage
2.2.2. Low
temperature
Pressure
Stream No.: S-79, S-80, S-86
197 | A p p e n d i x
No
1.1. No
flow
Less
1.2. Low
Flow
Flow
1.1.1. Large
blockage
1.1.2. Large
leakage
1.1.3. Line
rupture
1.2.1 Low
temperature
1.2.2. Low
pressure
1.2.3. Leakage
1.2.4. Blockage
1.1.I. No feed
flow
1.1.II
Chemicals lost
1.1.i. Install feed

indicator and alarm
1.1.ii. Regular
maintenance
1.1.a Replace the

faulty parts
1.1.b. Temporary
shut-down of DC-104
1.2.I. Less feed

flow to
subsequent part
1.2.i. Refer 1.1.i.

1.2.a Open control

valve
1.1.I. No feed
flow to
subsequent part
1.1.II Solvent
lost
1.1.i. Install feed

indicator and alarm
1.1.ii. Regular
maintenance
1.1.a Replace the

faulty parts
1.1.b. Temporary
shut-down of DC-104
1.2.I. Less feed

flow to
subsequent part
1.2.i. Refer 1.1.i.

1.2.a Open control

valve
No
1.1. No
flow
Less
1.2. Low
Flow
Flow
1.1.1. Large
blockage
1.1.2. Large
leakage
1.1.3. Line
rupture
1.2.1 Low
temperature
1.2.2. Low
pressure
1.2.3. Leakage
1.2.4. Blockage
Stream No.: S-83
198 | A p p e n d i x
1.1. No
flow
1.1.1. Large
blockage
1.1.2. Large
leakage
1.1.3. Line
rupture
Less
1.2. Low
Flow
1.2.1. Low
temperature
1.2.2. Low
pressure
1.2.3. Leakage
1.2.4. Blockage
More
1.3. High
Flow
1.3.1. High
pressure
1.1. No
flow
1.1.1. Large
blockage
1.1.2. Large
leakage
1.1.3. Line
rupture
No
Flow
1.1.I. No feed
flow to
subsequent part
1.1.II. Heat
exchanger
failure
1.1.III.
Overheat of
heat exchanger
1.2.I. Level in
RD-105
decreases
1.2.II. Overheat
of heat
exchanger
1.3.I. Level in
RD-105
increases
1.3.II. More
energy required
by heat
exchanger
1.1.i. Install feed

indicator and alarm
1.1.ii. Regular
maintenance
1.1.a Replace the

faulty parts
1.1.b. Temporary
shut-down of DC-104
1.2.i. Refer 1.1.i.

controller to RD-105
1.2.a Open control

valve
1.3.i. Refer 1.1.i.

controller to RD-105
1.3.a Open control

valve
1.1.i. Install feed

indicator and alarm
1.1.ii. Regular
maintenance
1.1.a Replace the

faulty parts
1.1.b. Temporary
shut-down of DC-104
Stream No.: S-84
Flow
No
1.1.I. No feed
flow to
subsequent part
199 | A p p e n d i x
More
1.2. High
flow
More
2.1. High
temperat
ure
Less
2.2. Low
temperat
ure
Temperatu
re
1.2.1. High
temperature
2.1.1. Lower
temperature of
cooling agent
2.1.2. Lower
flowrate of
cooling agent
2.2.1. Higher
temperature of
cooling agent
2.2.2. Faster
flowrate of
cooling agent
1.2.I. Level in
SO-106
increases

indicator and alarm
1.2.iii. Refer 1.1.ii

valve
2.1.I. Ignition
of hexane
2.1.II. High
pressure
2.1.i. Install
and alarm
2.1.a. Supply more

cooling agent
2.2.I. Low
pressure
2.2.II. Low flow
2.2.i. Install
and alarm
2.2.a. Supply less

cooling agent
200 | A p p e n d i x

Benzene Production Using Shale Gas

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Benzene Production Using Shale Gas

Caricato da

Copyright:

Formati disponibili

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E.

H83DPX Design Project Final Report

Chan Joel Kai Chin

Department of Chemical Engineering, University of Nottingham Malaysia Campus,

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

Executive Summary .................................................................... 1

I.2 Group Appraisal ................................................................................. 2

Production Overview ..................................................................... 5

Application and Uses .................................................................... 6

Market Survey ............................................................................. 7

Physical and Chemical Properties ................................................... 9

Review of Alternative Processes ................................................... 10

Economic Potential Evaluation...................................................... 15

III.8 Site Selection ................................................................................ 18

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

Plant Layout ............................................................................. 23

Section IV. Mass and Energy Balances ......................................................... D

Process Flow Diagram (PFD) ........................................................ 24

Process Description .................................................................... 25

Mass Balance ............................................................................. 28

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

Section I. Extended summary

Chan Joel Kai Chin

Department of Chemical Engineering, University of Nottingham Malaysia Campus,

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

I.2 Group Appraisal

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

Section II. Design Basis

Chan Joel Kai Chin

Department of Chemical Engineering, University of Nottingham Malaysia Campus,

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

II.1 Feedstock Capacity and Specifications

II.2 Production Capacity Specifications

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

Section III. Process Background

Chan Joel Kai Chin

Department of Chemical Engineering, University of Nottingham Malaysia Campus,

*Refer to AI.8 page 24 in the appendix for overall yield calculation.

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

III.1 Production Overview

C3H6, C4H8 &

Figure III.1 Process Block Diagram of the Proposed Process.

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

III.2 Application and Uses

Figure III. 2: Global Benzene Demand by Application (2014) (Merchant Research

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

III.3 Market Survey

Figure III.4.1: World Consumption of Ethylbenzene in 2014.

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

Figure III 4.2: Global Toluene

Figure III.4.3: Global Naphthalene

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

III.4 Physical and Chemical Properties

A.B. Verasingham, J.K.C. Chan, F. Prasetya, T.Y. Kim, Y.S.E. Soh

III.5 Review of Alternative Processes

C3+ compounds, water,