CHAPTER III

TECHNICAL ASPECTS AND REQUIREMENTS

This chapter presents the data and information as well as the assumptions

related to the technical aspects and economical information needed for the design

of the manufacturing plant. Standards were used to come up with a technically

viable design. Technical catalogues were used to carefully identify the design

specifications of each equipment. Three designs are presented and the best

design option will be selected through the worst case design philosophy.

Design Option 1

a. Process Design Layout

( insert picture of process flow diagram )

b. Process Description

There will be two streams of feed. One stream will contain ethylene

which will include an inert ethane as an impurity. Another stream will contain

ethylene. Ethylene from the feed tanks will travel and pass through a

compressor. Which is supplied with sufficient amount of electricity, to

increase pressure and convert it from gaseous phase to a liquid phase,

while benzene will pass through a pump, also, to increase its pressure. The

mixture of benzene and recycle benzene will be passing through a heater

to control its temperature before being fed to the alkylation reactor.

The resulting stream form the alkylation reactor mixed with the

resulting stream from the transalkylation reactor will pass through a cooler
 and enters a flash drum. The mixture will then go to the ethane separator

where ethane will go out from the top part while the other components will

continue to the first distillation column. Ethane is separated because if

ethane makes it through to the distillation column mistakenly, it would

significantly enhance the duty of the reboiler. The first distillation column will

have a distillate of a mixture of ethylbenzene and diethylbenzene, while

benzene will emerge at the top.The liquid stream which came out from the

first distillation column will now make its way to the second distillation

column which then separates the two components, while the benzene from

the distillate will serve as one of the feed in the transalkylation reactor. It will

be joined by diethylbenzene which is the distillate of the second distillation

column. Both will go through the transalkylation reactor where both reacts

and form ethylbenzene which will be recycled as inlet to the flash drum, to

mix with the output stream of the alkylation reactor. Ethylbenzene comes

out of the top of the second distillation column.

c. Major Equipment and their Function

d. Major Equipment Specifications

e. Components of the Plant

Together with the process that the plant operates with, listed below

are the other components of the plant necessary:

 Administrative Building

 Control Room

 Guard House
  Jetty

 Parking Lot

 Power Room

 Process Area

 Tank Farm

f. Land Area

The proposed Ethylbenzene Production Plant has an estimated land

area of 11,000 square meters which is bound to located at Brgy. Alas Asin,

Mariveles, Province of Bataan.

( insert plant layout )

g. Material Balance and Calculations
 Material balance is important for evolving the process flow diagram.

The material balance is simply taking into account of what enters and exits

an equipment or a process. Material balance can be done using molar or

mass balance, but mass balance will be used in the calculations below.

Assumptions:

1. Flow rates observes steady-state flow.

2. Behaviors of gases observes ideal gas law.

3. Projected ethylbenzene demand for the year 2029 is 63,600 MT per

year or exactly 10,000 kg/hr.

The focus of this design is the liquid alkylation of ethylene and

benzene to form ethylbenzene. An alkylation reactor will be used to

transform ethylene and benzene to ethylbenzene, while a transalkylator will

be used to transform diethylbenzene and benzene to ethylbenzene.

Diagram Calculation Efficiency

m1 m1 = 60,677.098 kg/hr

M-101 m3 m2 = 2943.493 kg/hr 100%

m2 m3 = 63,620.591 kg/hr

m3 = 63,620.591 kg/hr

m3 R-101 m4 m4 = (m3)(0.97) 97%

m4 = 61,711.973 kg/hr

m4 = 61,711.973 kg/hr

m4 D-101 m5 m5 = (m4)(0.99) 99%

m5 = 61,094.853 kg/hr
 m5 = 61,094.853 kg/hr

m6 m6 = (m5)(0.99)(3.4545 x 10-3)

m5 S-101 m6 = 208.942 kg/hr 98%

m7 m7 = (m5)(0.99)(0.997)

m7 = 60,302.453

m7 = 60,302.453 kg/hr

m8 m8 = (m7)(0.96)(0.839)

m7 C-101 m8 = 48,570.008 kg/hr 96%

m9 m9 = (m7)(0.96)(0.121)

m9 = 9,320.347 kg/hr

m9 = 9,320.347 kg/hr

m10 m10 = (m9)(0.96)(0.981)

m9 u
C-102 m10 = 8,777.530 kg/hr 96%

m11 m11 = (m9)(0.96)(0.019)

m11 = 170.003 kg/hr

m8 m8 = 48,570.008 kg/hr

u
M-102 m12 m11 = 170.003 kg/hr 100%

m11 m12 = 48,740.011 kg/hr

m12 = 48,740.011

m12 u
R-102 m13 m13 = (m12)(0.97) 97%

m13 = 47,277.811 kg/hr

h. Energy Balance and Calculations

 Diagram Calculation

Q1 = (60,677.098 kg/hr)(1.066 kJ/kg.K)

(303.15 K – 298.15 K)

Q1 = 323,408.9323 kJ

Q1 Q2 = (2,943.493 kg)(1.55 kJ/kg.K)

M-101 Q3 (303.15 K – 298.15 K)
Q2
Q2 = 22,812.07075 kJ

Q3 = (63,620.591 kg)(1.09 kJ/kg.K)

(303.15 K – 298.15 K)

Q3 = 346,732.221 kJ

Q3 = (63,620.591 kg)(1.09 kJ/kg.K)

(403.15 K – 333.15 K)

Q3 R-101 Q4 Q3 = 4,854,251.093 kJ

Q4 = (61,711.973 kg)(1.12 kJ/kg.K)

(403.15 K – 333.15 K)

Q4 = 4,838,218.683 kJ

Q4 = (61,711.973 kg)(1.12 kJ/kg.K)

(328.15 K – 313.15 K)

Q4 D-101 Q5 Q4 = 1,036,761.146 kJ

Q5 = (61,094.853 kg)(1.12 kJ/kg.K)

(328.15 K – 313.15 K)

Q5 = 1,026,393.53 kJ
 Q5 = (61,094.853 kg)(1.12 kJ/kg.K)

(333.15 K – 313.15 K)

Q5 = 1,368,524.707 kJ

Q6 Q6 = (208.942 kg)(1.766 kJ/kg.K)

Q5 S-101 (333.15 K – 313.15 K)

Q7 Q6 = 7,379.831 kJ

Q7 = (60,302.453 kg)(1.15 kJ/kg.K)

(333.15 K – 313.15 K)

Q7 = 1,386,956.419 kJ

Q7 = (60,302.453 kg)(1.15 kJ/kg.K)

(358.15 K – 328.15 K)

Q7 = 2,080,434.629 kJ

Q8 Q8 = (48,570.08 kg)(1.066 kJ/kg.K)

Q7 C-101 (358.15 K – 328.15 K)

Q9 Q8 = 1,553,271.158 kJ

Q9 = (9,320.347 kg)(1.73 kJ/kg.K)

(358.15 K – 328.15 K)

Q9 = 483,726.009 kJ

Q9 = (9,320.347 kg)(1.73 kJ/kg.K)

Q10 (413.15 K – 358.15 K)

Q9 u
C-102 Q9 = 886,831.017 kJ

Q11 Q10 = (8,777.530 kg)(1.726 kJ/kg.K)

(413.15 K – 358.15 K)
 Q10 = 833,250.923 kJ

Q11 = (170.003 kg)(1.946 kJ/kg.K)

(413.15 K – 358.15 K)

Q11 = 18,195.421 kJ

m8 m8 = 48,570.008 kg/hr

u
M-102 m12 m11 = 170.003 kg/hr

m11 m12 = 48,740.011 kg/hr

m12 = 48,740.011

m12 u
R-102 m13 m13 = (m12)(0.97)

m13 = 47,277.811 kg/hr

Design Option 2

a. Process Design Layout