Response-Content-Dispositionattachment FilenameDesign and Simulation of Cumene Manufact

Design and Simulation of Cumene Manufacturing Process
CHAPTER-1
INTRODUCTION
1.1 System Considered
Our target of the project is to design 1,00,000 tonne per year of 99.9wt % pure Cumene also
called as isopropyl benzene. Cumene is the principal chemical used in the production of
phenol and its co-product acetone on an industrial scale. It is also the starting material in the
production of acetophenone, methyl styrene, diisopropyl benzene and dicumyl peroxide.
Minor uses of cumene include as a thinner for paints, enamels, and lacquers; as a constituent
of some petroleum-based solvents, such as naphtha; in gasoline blending diesel fuel, and
high-octane aviation fuel. It is also a good solvent for fats and resins and has been suggested
as a replacement for benzene in many of its industrial applications.
Around 98% of cumene is used to produce phenol and its co-product acetone. However, the
requirement of cumene is largely dependent on the use of phenols derivatives which have
resulted in increasing requirement rates for cumene. The largest phenol derivative is
bisphenol-A (BPA) which supplies the polycarbonate (PC) sector. PC resins are consumed in
automotive applications in place of traditional materials such as glass and metals. Glazing
and sheet uses, such as architectural, security and glazing outlets, are also important PC
applications. The third largest use for PC is optical media such as compact discs (CDs) and
digital versatile discs (DVDs). Another phenol derivative is caprolactam which is used
mainly to make nylon 6. It is mainly the resin sector of the nylon market that is seeing
growth.
1.2 Motivation
The new trend in todays career prospect is the process designing which we both consider to
opt. We expect this project will help us to improve basics of process engineering and develop
an immense interest in the subject. While commencing the project we have applied all the
subject knowledge we have gained. We know process engineering covers the application of
CPC, FFO, HTO, MTO, and CRE to the process control.
With increasing demands of society, the industrialization is evolving. The need for clothing
food and health has become utmost issue. Speaking of health and clothing the important raw
materials are polymers and drugs or medicines. Phenol and acetylene plays important role in
Dr. Babasaheb Ambedkar Technological University, Lonere
Page 1
the production of both. And the cumene is the basic feed for these industries. Also cumene
being an organic compound, aromatic, has developed an intense interest among us.
Considering both social as well as personal interest, we chose to derive the design aspects of
the process for cumene manufacturing.
1.3 Objective
Considering the importance of present process, work was undertaken to design and simulate
the cumene manufacturing process both manually as well as ASPEN HYSYS. The objectives
of the present project are
To design cumene manufacturing process manually.
To carry out chemical engineering calculation using MS EXCEL.
To carry out simulations in HYSYS and verify the results obtained manually.
Page 2
CHAPTER-2
LITERATURE REVIEW
2.1 Industrial processes for manufacturing
There are various process developed for the manufacturing of cumene. Most important and
widely used in industry is alkylation of benzene and propylene. For this reaction to take place
we need catalyst. There is constant research going on for increasing yield and efficiency of
process by improving catalyst performance. Phosphoric acid catalyst, aluminium chloride
catalyst, zeolite catalyst developed by UOP and zeolite catalyst developed by
Exxonmobil/Badger.
2.1.1. Phosphoric acid catalyst process [12]
Figure 2.1 Acid Catalyst Processes

Cumene is typically produced commercially by reacting benzene and propylene in complete
liquid phase or mixed gas-liquid phase conditions in the presence of acid catalysts. Benzene
Page 3
feed in stoichiometric excess relative to the propylene feed is typically fed to the reactor to
control or minimize the oligomerization of the propylene which subsequently causes coking
and deactivation of the catalyst. Older processes based on solid phosphoric acid typically
employ a benzene to propylene feed ratio of about 8:1 molar. The high benzene to propylene
feed ratio employed in these processes is also needed to limit the production of
polyisopropylbenzenes, mainly diisopropylbenzenes and triisopropylbenzenes, as the
polyisopropylbenzenes produced over solid phosphoric acid (SPA) catalysts cannot be
converted to cumene effectively and have to be used as gasoline blending stock and regarded
as a process yield loss. The high benzene to propylene feed ratio also results in large amounts
of unconverted benzene in the reactor effluent that needs to be recovered by distillation and
recycled back to the reactor. Both of these factors make SPA processes uneconomical .
2.1.2. Aluminium chloride catalyst process [12]
Figure 2.2. Aluminium chloride catalyst

Aluminium chloride (AlCl3) is category of Friedel-Crafts type catalyst used to add alkyl
group to aromatic ring of benzene. The chemical reaction takes place at 130-135C
Page 4
temperature and 3.4 to 3.5 atm pressure. Due to exothermic nature heat is released during the
reaction. With the help of preheated feed is heated with the reactor effluent and even used to
generate steam. Two reactors are used to carry out the alkylation and transalkylation process.
Benzene is vaporised in a vaporizer and mixed with propylene. The feed stream is heated to
reactor condition along with catalyst. Alkylation reactor converts benzene and propylene to
cumene and diisopropylbenzene. The effluent stream is mixed with recycle stream of
polypropylbenzenes and passed into transalkylation reactor where it reacts with excess
benzene and convert into cumene.
Catalyst is separated from the organic compounds by a water wash in a separator. Separated
organic mixture is treated with caustic to remove the traces of acids. Catalyst is concentrated
with steam and recycled to alkylation reactor. Cumene is distilled out by a series of
distillation towers that splits out unreacted raw materials.
Several processes based on aluminium chloride catalysts, developed in the 1980s, have been
able to reduce the feed benzene to propylene ratio to about 3:1 molar, thus reducing the
capital and operating costs related to the recovery and recycle of excess benzene, and thus
improved the process economics somewhat. Although more polyisopropylbenzenes are
produced in the alkylation section of the aluminium chloride processes due to the lower
benzene to propylene ratios, the polyisopropylbenzenes produced in these processes can be
effectively trans alkylated with benzene to produce additional cumene, and the overall
process yield is improved significantly over those based on SPA catalysts. However, the
introduction of aluminium chloride as catalyst into the cumene plant brings with it a host of
environmental, plant maintenance, and plant and personnel safety issues due to the highly
corrosive nature of the catalyst. As a result, only a few cumene plants based on the
aluminium chloride processes have been built.
2.1.3. Zeolite catalyst process
There are two methods developed individually by Exxonmobil
zeolite catalyst and by UOP named Q-Max
[11] [5]
[2]
and Badger named beta
Page 5
Figure 2.3 Exxonmobil process

The introduction of zeolite catalysts based cumene technologies in the 1990s has
revolutionized the cumene manufacturing industry. Zeolite catalysts are non-corrosive and
environmentally benign. The use of zeolite catalysts thus eliminates the environmental,
maintenance, and safety concerns related to the aluminium chloride catalysts. The zeolite
based processes are able to produce cumene at higher product purity and process yield than
those based on solid phosphoric acid. Most zeolite based technologies are able to effect
alkylation at mild conditions and with feed benzene to propylene ratios between 6:1 and 3:1
molar, somewhat lower than those employed in processes based on solid phosphoric acid,
while limiting propylene oligomerization and catalyst coking to achieve a catalyst cycle
length of one to two years. More advanced zeolite based technology, such as the
Page 6
Mobil/Badger[2] cumene technology licensed by Badger Licensing, are able to operate at

extremely low benzene to propylene ratio of 2:1 molar or lower while achieving catalyst
cycle lengths of five years or more. Although more polyisopropylbenzenes are produced at
low benzene to propylene ratios, they can be very efficiently transalkylated with benzene to
produce additional cumene, and their effect on overall process performance is negligible.
Moreover, the significant reduction in the amount of unconverted benzene that has to be
recovered by distillation and recycled to the reactor results in significant reductions in both
capital investment and operating costs of the cumene plant.
The process licence by Exxonmobil is widely used. SABIC and many other companies in
Saudi Arabia employ this process. Also major cumene manufacturer from china are using
Exxonmobil/Badger process.
2.1.3.1 Q-Max Process [11] [5]
Figure 2.4 Q-Max processes

The Q-MAX
[11]
process provides a very good cumene yield and quality. The QZ-2000
zeolite based catalyst utilized for the Q-MAX process which operates with a low flow rate
of benzene and hence investment and utility costs are reduced greatly. QZ-2000 is noncorrosive and regenerate-able. Compared to other zeolite based cumene technologies, the
QMAX process provides the highest product quality and great stability. Impurities in the
fee have less effect. The alkylation reactor is divided into four catalytic beds present in a
single reactor shell. The fresh benzene feed is passed through the upper-mid section of the
depropanizer column to remove excess water and then sent to the alkylation reactor. The
Page 7
recycle benzene to the alkylation and transalkylation reactors is drawn from the benzene
column. This mixture of fresh and recycle benzene is charged through the alkylation reactor.
The fresh propylene feed is split between the catalyst beds and is fully consumed in each bed.
An excess of benzene helps in avoiding formation of poly alkylation and reduce the effect of
olefin oligomerization. As the chemical reaction occurs at exothermic condition, the
temperature increase during the alkylation reaction is controlled by the reactor effluent. The
temperature of inlet stream from the catalyst beds is further maintained to the designed
temperature by the circuit reactor effluent passing tubes which are cooled by the side stream
heat exchangers between the beds. Reacted effluent from the chemical reactor is fed to
depropanizer column which separates the propane and excess water. The bottoms stream of
the depropanizer column is fed to the benzene distillation column where excess benzene is
collected at top of the column and recycled to the process fed stream.
The benzene distillation column bottom stream fed to the cumene rectifying column where
cumene is recovered overhead. The cumene rectifying column bottom product is
diisopropylbenzene (DIPB), and fed to the DIPB rectifying column. The DIPB stream is
recycled to increase the conversion to the transalkylation reactor. The DIPB column bottom
products contains of heavy aromatic by-products, which are blended into fuel oil. High
pressure steam is used as heating medium to the fractionation columns.
The recycle DIPB from the overhead of the DIPB column combines with a portion of the
recycle benzene and is charged down flow through the transalkylation reactor. In the
transalkylation reactor, DIPB and benzene are converted to more cumene. The effluent from
the transalkylation reactor is then sent to the benzene column. The new QZ-2001 catalyst is
utilized in the alkylation reactor while the original QZ-2000 catalyst used for the
transalkylation reactor. Catalyst life time is about 24 years.
The Q-Max process typically produces near equilibrium levels of cumene (between 85 and
95 mol %) and DIPB (between 5 and 15 mol %). The DIPB is separated from the cumene and
is reacted with recycle benzene at optimal conditions for transalkylation to produce additional
cumene.
2.2 Chemistry of Cumene Manufacturing
The following reaction mechanisms are proposed for the alkylation of benzene to cumene
process. The major reactions taking place are alkylation and trans-alkylation. The other
Page 8
reactions involved include isomerisation and dis-proportionation. The reaction mechanism as

well as the reaction kinetics may vary depending on the catalyst used. The reaction can
proceed by with or without carbonium ion intermediate. The rates of reaction data was
obtained for different catalysts from the work done by various researchers. The kinetic data
and the reaction conditions specified by for a particular catalyst have been used in the present
work.
The reaction kinetic data [5] [1] is shown below
C3H6 + C6H6
K = 2.8 107
C9H12
E (kJ/kmol) 104174
Rate=kCpCb
C3H6 + C9H12
K = 2.32 109
C12H18
E (kJ/kmol) 146742
Rate=kCpCc
(The unit for rates is kmol s-1 m-3)
Trans-alkylation reaction
K= 6.52 10-3 exp (27240/RT)
Alkylation [5] [1]
Page 9
Isomerisation [5] [1]
Transalkylation [5] [1]
2.3 Cumene
Cumene is an organic compound that is based on an aromatic hydrocarbon with an aliphatic
substitution. It is a constituent of crude oil and refined fuels. Commercial production of
cumene is by Friedel-Crafts alkylation of benzene with propylene. During World War II,
cumene was used as an octane enhancer for piston-engine aircraft fuel. Presently, most of the
Page 10
worldwide supply of cumene is used as a raw material for phenol production, a process that
simultaneously produces most of the worldwide supply of acetone. Typically, cumene is
produced at the same facility that manufactures phenol and acetone. Cumene is also used as
an octane enhancer in the motor gasoline. Cumene commonly known as isopropylbenzene is
stable but may form peroxides in storage if in contact with the air. It is important to test for
the presence of peroxides before heating or distilling. The chemical is also flammable and
incompatible with strong oxidizing agents. Environmental laboratories commonly test
isopropylbenzene using a Gas chromatography-mass spectrometry instrument.
Table 2.1: Material safety data sheet [14] for cumene
Sr.
No.
Properties
Description
1.
Structural formula
2.
Chemical Formula
3.
Molecular weight
120gm/mole
4.
Boiling Point
152.4C
5.
Melting Point
-96C
6.
Specific Gravity
0.862
7.
Vapour Pressure
8mm of Hg
8.
Vapour Density
4.14
9.
Corrosivity
Non-corrosive in presence of glass.
Page 11
10.
Solubility
Very slightly soluble in cold water.
The substance is toxic to lungs, the

nervous system, and mucous
11.
Toxicity
membrane.
Very hazardous in case of skin

contact, of ingestion, of inhalation.
2.4 Benzene
Benzene is an organic chemical compound with molecular formula
. Benzene is
classified as hydrocarbon as its constitutes are only carbon and hydrogen. Benzene is natural
constituent of crude oil, and is one of the most elementary petrochemicals. Benzene is an
aromatic hydrocarbon. It is mainly used as precursor to heavy chemicals, such as
ethylbenzene and cumene, which are used on a billion kilogram scale. Because it has a high
octane number, it is an important component of gasoline.
Benzene is used as intermediates for many chemicals such as ethylebenzene, cumene,
cyclohexane, and styrene. Cumene is converted to phenol for resins and adhesives. Styrene is
used to make polymers and plastics. Cyclohexane is used to the manufacture of Nylon.
Smaller amounts of benzene are used to make some types of rubbers, lubricants, dyes,
detergents, drugs, explosives and pesticides.
Table 2.2 Material Safety Data Sheet for Benzene [14]
Sr.
No.
Properties
1.
Structural formula
2.
Chemical Formula
3.
Molecular weight
Description
78.11g/mole
Page 12
4.
Colour
Clear colourless, colourless to light yellow
5.
Boiling Point
80.1C
6.
Melting Point
5.5C
7.
Specific Gravity
0.8787
8.
Vapour Pressure
10kPa
9.
Vapour Density
2.8
Miscible in alcohol, chloroform,

carbon disulfide oils, carbon
10.
Solubility
tetrachloride, glacial acetic acid,

diethyl ether, acetone.
11.
Stability and reactivity
Very slightly soluble in water.
Benzene vapours + Chlorine and

light causes explosion.
Highly reactive with oxidizing

agents, acids.
12.
Flash Point
-11.1C
2.5 Propylene
Propylene also known as propene is a gas having bad odour. It is colourless. Propene is
produced from fossil fuels-petroleum, natural gas and coal. A major source of naphtha
cracking. Propene can be separated by fractional distillation from hydrocarbon mixture
obtained from cracking and other refining processes.
Propene is second most starting product in petrochemical industry after ethylene. It is raw
material for a wide variety of products. Propene and benzene are converted to acetone and
phenol via cumene process. Propylene is also used to produce isopropanol, acrylonitrile, and
propylene oxide.
Page 13
Table 2.3 Material Safety Data Sheet for Propylene [14]

Sr.
No.
Properties
Description
1.
Structural formula
2.
Chemical Formula
3.
Molecular weight
42.08g/mole
4.
Colour
Colourless gas
5.
Boiling Point
-47C
6.
Freezing Point
-301C
7.
Density
1.7855g/L
8.
Vapour Pressure
7828mmHg
9.
Vapour Density
1.5
10.
Solubility
11.
Stability and reactivity
Soluble in alcohol, ether, acetic

acid.
May polymerize.
May react on contact with air, heat,

light, water.
12.
Flash Point
-108C
Page 14
The collection of material safety data sheet helps allot during designing process. During the
designing of a storage tank or a reactor the chemical as well as physical properties of the
reacting mixture and product is considered. Toxicity, corrosivity, vapour pressure are
important factors considered during the designing of the storage tank.
Other factors such as fire and health hazards related to a specific chemical are important in
layouting of the plant. The piping and utility sections are also designed according to the
reaction requirements.
Page 15
CHAPTER-3
MATERIAL BALANCE
3.1 Overall Material Balance
Basis: Per hour of operation
Amount of cumene to be obtained = 1,00,000 ton of cumene per annum.
=
=
tons per day of cumene.

tons of cumene per hr.
= 12.626 x
kg of cumene per hr.
= (12.626 x
)/120.19 Kmoles of cumene per hr.
= 105.2189 Kgmole/hr
Assuming 97% conversion and no loss in DIPB.
Hence Cumene required = 105.05/1=105.2189
= 12626.26 Kg/hr.
Hence 12606 kg of cumene is required to be produced per hour.
Propylene required = 105.05/0.98 = 108.473 Kgmoles/hr.
= 108.473 x 42 Kg/hr of propylene
= 4555.686 Kg/hr of propylene
Assuming Benzene required is 25% extra,
= 108.473 x 1.25 Kmoles of benzene
= 135.5913 Kgmole/hr
= 10576.12 Kg/hr
Page 16
Propane acts as an inert in the whole process. It does not take part in the chemical reaction.
Also it is inevitably associated with the propylene as an impurity as their molecular weight is
very close. We assume propylene to propane ratio as 3:1.
Being an inert we neglect propane balance in the material balance to avoid complexity.
3.2 Material Balance around Reactor
Propylene = 4555.868 Kg/hr
Benzene = 10576.12 Kg/hr
Products:
Reactor
Cumene =12626.26 Kg/hr
Benzene in product = 135.375-105.05 = 30.37145 Kmoles/hr

= 2369.051 kg/hr
Input = 4555.868 + 10576.12 = 15131.99 kg/hr
Output = 12626.26 + 2369.051=14995.31 kg/hr
Input = Output
3.3 Material Balance around Columns
Distillation column: (Depropanasing Column)
Assuming almost all the propane is removed in depropanising column and sent to storage
tank. Hence material balance for depropanasing column is not considered.
Distillation Column: (Benzene Column)
F=D+W
15131.99 = D + W
F.Xf = D.Xd + W.Xw
Page 17
F = Benzene + Cumene =15131.99Kg/hr

Xf = (2369.051/15131.99) = 0.156559
D = Benzene =1593.602 Kg/hr

W= Cumene = 13822.59 Kg/hr
Taking Xd = 0.99
Xw = 0.09
15131.99 x 0.156559 = 0.99 x D + 0.05 x W
2369.051 = 0.99 x D + (15131.99 D) x 0.05
D = 1593.602 Kg/hr = Benzene
W= 13822.59 Kg/hr = Cumene
Input = 15131.99 Kg/hr
Output = 15416.19 Kg/hr
Assuming all the Benzene present in benzene column is recycled to the feed. Hence
considering negligible amount of benzene to be part of residue. This will avoid complexity of
again distillation of cumene.
Therefore amount of Benzene recycled = 1593.602 Kg/hr
Therefore feed actually given to the system = 15416.19 + 1593.602 = 16725.59 kg/hr.
3.4 MS Excel Spread Sheet for Material Balance
Table 3.1 Given Data
Parameter
Molecular wt of propylene
Molecular wt of cumene
Reaction temperature
Reaction pressure
Conversion of propylene
Molar flow rate of cumene
value
Unit
Gram
Gram
K
Atm
42
120
633
25
0.97
833333.3 kmol/year
Page 18
Product cumene outflow
100000 tonne/year
Table 3.2 Overall material balance ExcelSheet

Overall Material Balance
amount of cumene to be
obtained
assuming 0% loss due to

DIPB, cumene required
propylene required , (Fa0)
benzene required is 25%
extra (Fb0)
since propane is inert it is not considered in the reactor

material bal
100000 tonne/year out
303.0303
12.62626
12626.26
105.2189
tonne/day
tonne/hr
kg/hr
kmol/hr
105.2189
12626.26
108.473
4555.868
kmol/r
kg/hr
kmol/hr
kg/hr
135.5913 kmol/hr
10576.12 kg/hr
assuming 330 working

out days
out
out
out
loss is due to
polymerization of cumene
out to DIPB
out
in conversion is 97%
in
in
in
Table 3.3 Material Balance Reactor ExcelSheet

Material Balance Reactor
formation of DIPB
benzene required for DIPB
benzene in product
total inflow
total outflow
0
0
0
30.37245
2369.051
15131.99
14995.31
considering no
kmol/hr generation,out polymerization
kmol/hr
kg/hr
kmol/hr Out
kg/hr
Out
benzene +
kg/hr
propylene
kg/hr
Table 3.4 Material Balance for Depropanizer ExcelSheet

Material Balance (Depropanizer,
col.1)
we can ignore this since it is assumed that 100%

propane is recovered from the depropanizer.
Page 19
Table 3.5 Material Balance for Benzene Column

Material Balance (Benzene column col.2)
F
xF
xD
xW
F*xF
F*xF = D*xD + W*xW
15440.81 = D + W
from above two eqns calculate D, W
D
W
Input
Output
amount of benzene recycled
feed actually given to the system
15131.99 kg/hr
0.156559
0.99
0.05
2369.051
eqn1
eqn2
1593.602
13822.59
15131.99
15416.19
1593.602
16725.59
kg/hr
kg/hr
kg/hr
kg/hr
kg/hr
kg/hr
Benzene
Mixture
Page 20
CHAPTER-4
ENERGY BALANCE
4.1 Basis Calculations
Basis: Per hour of operation
The gases viz. Propylene, Propane, Benzene enters at 25C and benzene enters at 80C,
pressure is 1 atm.
Table 4.1 Given Data
To calculate the temperature of the mixture of gases after compression to 25 atm
Cp
Unit
Propylene (A)
64.18 J/mol K
Propane (C)
73.89 J/mol K
Benzene (B)
82.22 J/mol K
Propylene in feed
108.473047 kmole/hr
Benzene in feed (Benzene fed+Recycle benzene)
165.963761 kmole/hr
4.1.1 Average Specific heat capacity calculations
Assuming that propylene is accompanied with propane as impurity in the ratio 3:1.
Therefore propane in the feed = 36.1576822 kmole/hr
Hence,
=0.4838,
=0.3529,
=0.1290
4.1
4.1.2 Temperature of the stream after mixing:

Table 4.2 Specific Heat Capacity of Compounds [7]
Component
Cp at 30C
Units
Propylene (A)
64.52 J/mol K
Propane (C)
70.17 J/mol K
Benzene (B)
98.2 J/mol K
Derive an Equation for Calculating T:

(1105.09 x 64.52 + 1381.36 x 98.20 + 368.36 x 70.17) x 10 3 x (T-25) = 204.73 x 86.22 x 10 3
x (80-T)
Page 21
or, 14.18T=409.5
or, T=29C
Now we have to find
Table 4.3 Given Data for Temperature and Pressure
Variables
Value Unit
29 C
P1
1 Atm
P2
25 Atm
T1
29 C
We get,
=
4.2
= 42.06C
4.1.3 Molar Flow-rate Calculations
Assuming that the exit stream from Preheater leaves at 100C
For the products from the reactor,
m = cumene+Benzene+propane
4.3
=105.2189 + 30.37245 + 36.157 =171.7489 kmol/hr
To find
at (250+100)/2 = 175C
= 0.6126205.24+0.1673121.19+0.2105107.76
Table 4.4 Specific Heat Capacity ExcelSheet
Propane
Cumene
Propylene
Benzene
Cp(avg) 175C
107.76
205.24
97.6
121.19
168.688591
J/mole K
J/mole K
J/mole K
J/mole K
J/mole K
For the reactants leaving the pre-heater:

m= propylene+benzene+propane
4.4
Page 22
= 108.47+135.59+36.15
= 280.222 k moles/hr
4.2 Heat balance Around the Pre-heater
11749.72 x 168.22 (250-100)x103= 3059.54 x 91.38 x (T 42.19)x103
4.5
T 200 C
The reactants have to be further heated to the reaction temperature of 360C before being
fed to the reactor.
To find saturated steam required:
Cp avg of reactants has to be determined at (200 + 360 )/2=280C
Table 4.5 Specific Heat Capacity ExcelSheet
Component
Cp
Unit
Propane
118
J/mol K
Propylene
98
J/mol K
Benzene
142
J/mol K
= 0.361298+0.5184142+0.1204118 = 123.2176 J/mol.K
4.6
We have = 2676
m
(360-200)=
280.222123.21761000(360-200) =
4.7
x 2676
= 21.028 x 106 kg /hr

4.3 Energy Balance Around the Reactor
Enthalpy of reactants + heat evolved = Q + Enthalpy of products
4.8
m Cp dT reactants + heat evolved = Q + m Cp dT products
4.9
Heat evolved = 23.7683 kcal/mol
Page 23
=99.3964 kJ/mol
Moles of cumene produced = 105.218855 kmol/hr
Heat evolved
=99.3964 105.2188 1000
4.10
=10458652.2kJ/hr
Table 4.6 Given Data[7]
Given
Cp
Propylene
87.37
Benzene
93.97
Propane
97.34
m Cp dT reactants = 108.473100087.37 (360 25)+135.591393.971000(36025)+36.157697.341000 (360-25)
4.11
= 8622362026kJ/hr
m Cp dT products = 36.1576100097.34(360 25)+105.218993.971000177.07
(360 25)+30.37245100093.97(360 25)
4.12
= 8376604949kJ/hr
m Cp dT reactants +
= Q + m Cp dT products
8622362026 + 10458652.2 = Q + 8376604949

Q= 256215729kJ/h
Page 24
CHAPTER-5
REACTOR CALCULATIONS
5.1 Volume Calculations
From the literature review we have taken plug flow reactor[11]. The material of construction is
stainless steel.
The key equation to calculate the volume of the reactor is:
5.1
5.2
The reaction rate constant
can be calculated using Arrhenius Equation.

5.3
Before going for the reactor volume calculation we need to obtain the data for the volume
calculations. The main factors affecting the reactor volume is reaction rate constant
concentration of basis component
reaction
, Molar flow-rate of basis component
initial
, rate of
and Conversion X.
The data was obtained step by step starting with density.

Density of Propylene
: 0.02 kg/l
Density of Benzene
: 0.0376 kg/l
Density of Cumene
: 0.0297 kg/l
Mass flow rate of Propylene
: 4555.868 kg/hr
Mass flow rate of Benzene
: 10576.12 kg/hr
Mass flow rate of Cumene
: 12626.26 kg/hr
For calculation of the volumetric flow-rate we consider following standard formula:

5.4
Page 25
Volumetric Flow-rate of Propylene
Volumetric Flow-rate of Benzene
Volumetric Flow-rate of Cumene
= 227784.3 lit/hr
= 281279.787lit/hr
= 227784.3 + 281279.787
= 509064.087 lit/hr
=509.06
The main formula we used is

5.5
Where,
is Molar Flux of Propylene
is Volumetric flowrate
Initial concentration of Propylene
Initial concentration of Propylene
kmol/l
kmol/l
Now we calculated reaction rate constant
Taking
T= 623K
R=1.98kcal/mol.K
= 34300.5797 mol/l.s=123482.08kmol/l.hr
Now putting all the above values in the rate law equation:
But
Page 26
5.6
5.7
Reactor volume
As we are taking propylene as basis we consider volumetric flow-rate of the propylene.
On substituting value of
, we integrate the equation and obtained the following equation:

5.8
Now substituting the obtained data we got,
The last calculation is of residence time

5.9
The residence time helped us compare the simulator and manual calculations acutely.
5.2 Reactor Cooling Arrangement Calculations
5.2.1 Calculation of Heat Transfer Area
We know,
Page 27
5.10
From the simulator we have got values of

Q = 2.489
kJ/hr
= 6913889J/s
= 260C = 533K
5.11
Table 5.1 Given data Reactor Cooling
Do
Di
4.056
4.06
7500
60
0.05
50.2
M
M
W/
K
W/
K
M
W/m K
water
Cumene
On putting above values in the equation 5.11 we get,
= 59.506 W/
Now putting all the values in the equation 5.10 we get,

533
To achieve this area for heat transfer we will need to insert tube bundles from inside the
reactor.
5.3 Cooling Tube Calculations
We have surface area
Page 28
We will use standard L = 10m and D = 2cm(0.02m) tubes
To achieve the surface area
for heat transfer we need to find out number of tubes
needed.
In this way we can easily control the reaction by inserting 346 numbers of tubes in the
reactor.
Page 29
CHAPTER- 6
SIMULATION RESULTS IN ASPEN HYSYS
6.1 HYSYS software
The goal of programs like HYSYS and Aspen is, of course to provide you with the capability
to design an eentire process as completely and accurately as possible. Most (though not all) of
the difference between the two lie in their user interfaces.
Unlike Aspen, HYSYS does not wait until youve entered everything before beginning
calculations. It always calculates as much as it can at all times and results are always
available, even during calculations. Any changes that you make to the data are automatically
propagated throughout the program to anywhere that entry appeas and all necessary
recalculations are instantly carried out. It tends to be a lot easier to catch errors this way as
you build your simulations. However, there are times when you will not want HYSYS
calculating the entire flowsheet over again every time you make a small change. Hence, the
existence of the environments. While you are in one environment, calculations in the other
environments are placed on hold. Every case has two or more environments. The one that
contains all the items you expect to see, the streams, unit operations such as reactors,
separators, columns, mixers, etc., and various utilities, is the simulation environment. At the
top of that environmental hierarchy is the case environment and the main flowsheet. Though
the entire simulation may be placed in the main flowsheet, columns and templates are
automatically brought in as sub-flowsheets. Sub-flowsheets can be thought of as modular
programs. You can have as many as you like, nested as deep as you like.The other
environment, and the one you actually have to deal with first when you start a case, is the
basis environment. The basis environment is the place that you define the thermodynamic
package you wish to use (Peng-Robinson, Margules, etc.), the components that will be used
in your simulation and any reactions that may occur. Is dealing with a Petrochemical
application, there is also an oil environment that may be reached only from the basis
environment.
There are two files that HYSYS reads whenever you start HYSYS. One of these is the
Preference File, the other is the workbook format file. The preference file tells HYSYS many
important things like which units you want to use, where to look first for your stored files etc.
You can have multiple preference files saved, but the one that is loaded upon startup is the
file named hysys.prf in the directory from which HYSYS is started. If you lunch HYSYS
Page 30
from your start menu, your users profile has been configured with Y:\Hysys as the start
directory. That is the file that must be overwritten if you want to make changes to your
default preferences.
6.2 Simulation Working Methodology
Since HYSYS is continuous simulator working methodology was simple. We started from
defining inlet stream and then adding next operation only when all previous system was
converged. This gave clear idea of mistakes at the moment.
6.2.1 Components and reactions
Benzene, propylene and Cumene are the components required to be selected from the
database. Once the component are selected Peng-Robinson fluid package is selected. Then we
have to add reactions. Since reactor is PFR we have to use kinetic relations set. The data
required is stoichiometric ratios and Arrhenius equation data and basis component. Basis in
this case is propylene.
6.2.2Conditioning on the feed
Reactor has specific feed requirement. Temperature of 360 degree centigrade and pressure
2533 kPa is required. So first of all converged feed streams were mixed in a mixture a nd
passed through a preheater.
6.2.3 Reactor[17]
The selected reactor is PFR. We first add reactions to this reactor. Conversion achieved is
97%. In the Rating tab we specify volume and other dimensions. Since outlet temperature
conditions are known we get duty calculated by HYSYS.
6.2.4 Propane Column
Inlet temperature is kept at 92 degree centigrade and pressure 2533 kPa as given in Turtal et
al. Column stages calculated by HYSYS are four with feed entering on second stage. All
propane present as impurity in feed is removed from this column top. Bottom is send to next
column.
6.2.5 Cumene column
Entering temperature is 92 degree centigrade and pressure 175 kPa. Our target is producing
99% pure Cumene. For that HYSYS has calculated 30 stage tower inlet stag as fifteenth
stage. Reflux rate if 15kmole/hr. Bottom of this column is 99 wt% pure Cumene with molar
flow rate of 98.77 kmole/h. Top product is benzene which is send back for recycle.
Page 31
6.3 Process flow-sheet in ASPEN HYSYS
Figure 6.1 Flow sheet of Cumene manufacturing process in HYSYS
Page 32
6.4 Results Spreadsheets

6.4.1 Material balance
Name
Pressur
e [kPa]
Temper
ature
[C]
Mass
Flow
[kg/h]
Table 6.1 Material Balance HYSYS Result in ExcelSheet

Benz propy heate react coole prop mix
5
cume
ene
lene
d
or
d
ane
benz
ne
feed outle prod
cume
prod
t
101. 101.3 101. 2533 2533 506. 101. 2533 101
325
25
325
.125 .125 625
325
.125
25
25
360
647. 92.5 2.34 148. 360
153.
487
6967 6205
5604
1057
6.09
4575. 1515
419
1.51
1515
1.52
1515
1.52
237.
7097
1491
3.81
1515
1.51
1187
1.06
benz
ene
re
100
175
130.
1678
90
3042
.748
1491
3.81
6.4.2 Benzene Column

Table 6.2 Benzene Column HYSYS Result ExcelSheet
Distillation
Name
Number of Stage
Top Stage Temperature [C]
Bottom Stage Temperature
[C]
Top Stage Pressure [kPa]
Bottom Stage Pressure [kPa]
Reboil Ratio
Reflux Flow/Total Liq Flow
Condenser Duty
Reboiler Duty [kJ/h]
T-101
30
130.1678
153.5604
100
101
0.576926
3589107
6.4.3 Propane column

Table 6.3 Propane Column HYSYS Result ExcelSheet
Name
T-100
Minimum Reflux
0.063002
External Reflux
15
Minimum Trays
3.246272
Actual Trays
3.373717
Optimal Feed
2.646473
Rectify
Vapour
Flow 85.56353
[kgmole/h]
Rectify Liquid Flow [kgmole/h] 80.21581
Stripping
Vapour
Flow 85.56353
[kgmole/h]
Page 33
Stripping
Liquid
Flow
[kgmole/h]
Light Key Mole Frac
Heavy Key Mole Frac
Condenser Pressure [kPa]
Reboiler Pressure [kPa]
Condenser Temperature [C]
Reboiler Temperature [C]
Condenser Duty [kJ/h]
Reboiler Duty [kJ/h]
210.3294
0.001
0.001
506.625
101.325
2.346967
148.6205
1632255
3312263
6.4.4 PFR Reactor

Table 6.4 PFR HYSYS Results ExcelSheet
Name
Pressure Drop [kPa]
Reactor Volume [m3]
Tube Length [m]
Tube Diameter [m]
Void Volume [m3]
Particle Diameter [m]
Particle Sphericity
Solid Density [kg/m3]
Solid
Heat
Capacity
[kJ/kg-C]
Number of Tubes
Minimum Step Fraction
Minimum Step Length
[m]
Number of Segments
Wall Thickness [m]
Bulk Density [kg/m3]
PFR-100
0
129.56
10
4.061538
103.648
0.001
1
2500
250
1
0.000001
0.00001
20
0.005
500
Page 34
CHAPTER-7
SUPPORTS
The method used for designing support is taken from literature[6] . Material used is carbon
steel and thickness is calculated.
7.1 Reactor Support

We will provide skirt support to the reactor.
(a) Stress due to dead weight
7.1
W= dead weight of the reactor = 800,000 kg (calculated considering various assumptions)
Do= outside diameter of skirt = 7.8 m
Tsk = to be calculated
7.2
(b) Stress due to wind load
7.3
= 43680 N
Flw = force
p1= wind pressure on the vessel = 800 N/mm2
h1 = height of the rector
k = coefficient depending on the shape factor = 0.7 (for sphere)
Do = OD skirt = 7.8m
The bending moment due to wind at the base of the vessel
7.4
Mw = 218400 N-mm
Stress,
7.5
7.6
Page 35
We can assume permissible stress as 140 N-m (Joshi Mahajani), hence
Hence thickness of the reactor skirt support, Tsk,

Tsk = 199.9285 mm = 19.992 cm
7.2 Depropaniser Support
We will provide skirt support to depropaniser column.
We will provide skirt support to the reactor.
(a) Stress due to dead weight
7.7
W= dead weight of the reactor = 500,000 kg (calculated considering various assumptions)
Do= outside diameter of skirt = 0.91 m
Tsk = to be calculated
7.8
(b) Stress due to wind load
7.9
= 17476.095 N
Flw = force
p1= wind pressure on the vessel = 1500 N/mm2
h1 = height of the rector
k = coefficient depending on the shape factor = 0.7 (for sphere)
Do = OD skirt = 0.91m
The bending moment due to wind at the base of the vessel
7.10
Mw = 159818.88 N-mm
Stress,
Page 36
7.11
7.12
We can assume permissible stress as 140 N-m (Joshi Mahajani), hence
Hence thickness of the reactor skirt support, Tsk,

Tsk = 505.88 mm
Page 37
CHAPTER-8
LAYOUT AND PLOT PLAN
8.1 Introduction
The major activities of plant layout designing is to achieve an optimum plant
configuration taking place during the study phase of the project.
The design of any processing plant is usually accomplished in three phases: conceptual,
study, and detail conceptual designs are made when sketchy or minimal information is
used to prepare an abstract arrangement of a plot plan or an equipment and piping layout.
Preliminary, or study phase, design are made with unchecked or uncertified data to design
a facility in sufficient detail so that the documents produced can be used for detail design,
confirmation of purchased equipment, and the purchase of bulk materials. In the detail
phase, all designs are finalized. The designs use such checked data as steel and concrete
drawings, hydraulics and certified vendor drawings for equipment, valves and
instruments.
8.2 Process Flow Diagram [5]
This document schematically shows all major equipment items within a plant and how
they are linked together by piping, ducts, and conveyors. It shows equipment number,
flow rates and operating pressures and temperatures and is used to prepare the mechanical
flow diagrams (i.e. piping and instrumentation diagrams). It is also used to prepare
conceptual and preliminary plot plans.
8.3 Layout and Spacing[5]
Wherever explosion or fire hazard exist, proper plant layout and adequate spacing
between hazards are essential to loss prevention and control. Layout relates to the relative
position of equipment or units within a given site. Spacing pertains to minimum distances
between unit and equipment.
This Project Engineering Standard covers the basic requirements of the plant layout and
spacing of oil & gas refineries, petrochemical and similar chemical plants to ensure safety
and fire prevention together with ease of operation and maintenance.
8.4 Definitions and Terminology[5]
Page 38
8.4.1 Boundary- Boundary of the equipment is the term used in a processing facility, by
an imaginary line that completely encompassed the defined site.
8.4.2 Pipe Rack- The pipe rack is the elevated supporting structure used to convey piping
between equipment. This structure is also utilized for cable trays associated with electricpower distribution and for instrument tray.
8.4.3 Plot Plan- The plot plan is the scaled plan drawing of the processing facility.
8.4.4 Tank Spacing- Is the unobstructed distance between tank shells, or between tank
shells and the nearest edge of adjacent equipment, property lines, or buildings.
8.4.5 Natural elevation for location of upstream / downstream units and equipment (such
as feed and product storage tanks, wastewater plant, oil/ water separator, etc.) and
arranged as follows:
The process area shall be located in the most convenient place for operating the
process Unit. The units shall be separated by roads. Major roads shall have minimum
width of 10 m., with maximum length of 400 m. The minor roads shall have minimum
width of 6 m. (Minor roads shall not be in an area classified as zone 0 or 1). A plant
may contain one or several process units. Where any unit processes flammable fluids
and may be operated independently ( i.e. one unit may be shut down with others in
operation ). The minimum spacing between equipment on the two adjacent units shall
be at least 20 m.
The storage area shall be located as far as possible from buildings occupied by
personnel at the site, but should be located near the process area for ready operation of
the feed stocks and product run downs.
The utilities area shall be located beside the process area for ready supply of utilities.
Except where they are an integral part of a process unit, site utility units should be
grouped together in an area classified as nonhazardous.
Loading and unloading area shall be located on a corner of the site with capable
connection to public road directly, for inland traffics. Loading/unloading areas for
road transport shall have adequate space to provide access for filling, parking and
maneuvering. A drive through rack arrangement is preferred. The loading and
unloading facilities should be downwind or crosswind from process units and sources
Page 39
of ignition, based on the direction of prevailing wind. For marine transportation, the
area shall be located on the seaside or riverside in the plant site.
The administration and service area shall be located at a safe place on the site in order
to protect personnel from hazards. It shall preferably be located near the main gate
alongside the main road of the plant.
Flare and burn pit shall be located at the end of the site with sufficient distance to
prevent personnel hazard.
Waste water treating Unit shall be located near at the lowest point of the site so as to
collect all of effluent streams from the processing Unit.
The process unit to which the feed stock is charged first, shall be located on the side
near the feed stock tanks, to minimize the length of the feed line.
The process unit from which the final product(s) is (are) withdrawn, shall be located
on the side near the products tanks to minimize the length of the product run-down
line.
Process Units, in which large quantities of utilities are consumed, should be

preferably located on the side near the utility centre.
Security fence:
- All sites (plants or complex) shall be within a security fence.
Fire water pumps and equipment shall be sufficiently remote from processing, storage
and loading areas, where a major fire could occur.
8.5 Roadways [5]

Road and access ways shall offer easy access for mobile equipment during construction
and maintenance, fire fighting and emergency escape in a fire situation. Access roads
shall be at least 3 m from processing equipment between road edges to prevent vehicle
collisions.
8.6 Pipe racks and Sleepers[5]
In general, pipe racks for process Units and pipe sleepers for the off-site facilities
shall be considered as the principals support of the pipe way. Run pipe lines overhead
should be grouped in pipe racks in a systematic manner.
Single level pipe racks are preferred, if more than one level is required, the distance
between levels oriented in the same direction shall be adequate for maintenance but
not less than 1.25 meters.
Page 40
Maximum pipe rack widths shall be 10 m. If widths larger than 10 m are required, the
pipe rack shall be designed to be of two stages.
Avoid flat turns. When changing directions, change elevation.
Allow ample space for routing instrument lines and electrical conduit. Provide 25%
additional space for future instrument lines and electrical conduit adjacent to that
required.
Provide 20% additional space on the pipe rack for future piping. This space shall be
continued and clear on each level for the full length of the rack. The width allocation
may be split in two sections but not more than two.
Allow a continuous clear area of 4 meters high by 4 meters wide below main racks in
process Units for maintenance access ways.
Overhead racks may contain more than one level. For steel pipe racks, the height of
levels shall have one of the following elevations:
Main pipe racks : 4.60, 6.20, 7.80 m
Individual or secondary pipe rack: 3.80, 5.40, 7.00 m. In special cases for
large size pipes or concrete pipe racks, the distance between the various floors
may be increased.
Except for special cases, minimum width of pipe rack shall be 6 m. The width of pipe
rack shall be designed to accommodate all pipes involved plus 20% space for future
expansion or modification.
8.7 Layout of Control Room and Electrical Sub-Station[5]
The control room and substation shall be located as close as possible to the plant
equipment, maintaining a minimum distance from viewpoint of noise and safety
requirements.
The control rooms, and substation shall be spaced at least 15 m from the nearest
process equipment surface. The control room and substation shall be located with
consideration to convenience in daily operation.
The control room shall be positioned so that the operator can command a view of the
whole system which is under control. Large buildings or equipment shall not be
placed in front of the control room.
8.8 Fire Fighting Requirements [5]
Page 41
Each individual process unit shall be provided with sufficient open spaces there
around that, fire trucks can be run and operated thereat. The width of access way there
to, shall be 6 meters minimum.
8.9 Access Requirements[5]

Access ways within the plant shall be provided for maintenance, emergency case, and for
fire fighting from the road around the plant. Piping system shall be laid in such a way to
make possible passage of mobile equipment. Operating passageway between equipment or
piping and adjacent equipment generally is 1050 mm minimum except when otherwise
shown on drawings.
Minimum widths of access way shall be as follows:
1. Vehicular access ways within units: 4.0 m
2. Pedestrian access ways and elevated walkway: 1.2 m
3. Stairways and platforms: 0.8 m
4. Footpaths in tanks areas: 0.6 m
5. Maintenance access around equipment: 1m
6. Fire truck access way: 6m
8.10 Process Requirements [5]
Equipment shall be laid out along the flows on the process flow diagram.
Especially, the fractionators and the reboiler, condensers and overhead receivers shall
be collectively located.
8.11 Safety Requirements[5]
All process equipment should be kept at least 15 meters from fired heaters.
Control rooms and their roadways shall not be located in hazardous area, classified in
project specification; generally, they shall be located at a distance of more than 15
meters from the nearest equipment.
8.12 Result
After going through all this literature we came up with following process plant layout. All the
safety as well as environmental norms are taken into consideration while designing the
layout.
Page 42
Figure 8.1 Process Plant Layouts

Page 43
CHAPTER-9
STORAGE AND HANDLING
9.1 Benzene
9.1.1 Handling and sampling
In any workplace where benzene is handled, used, stored or transported, a training program
must be implemented to ensure workers awareness of benzenes properties, toxicity, and
safety procedures. It should consist of the following points,
Benzene properties, such as high vapour pressure and flash point.

Benzene health hazards.
Benzene physical hazards including the potential for fire and explosion.
Benzenes primary routes for entry into body.
Safe work and good housekeeping practices.
The importance of protection from benzene contact; the proper clothing and cleaning
requirements.
The importance of respirators, their effectiveness, and health hazards effected by nonuse.
The importance of the exposure limits, such as permissible Explosion limits - Time
Weighted Average (1 ppm) and Permissible Exposure limit Short term exposure
limit (5 ppm).
Signs and symptoms of benzene exposure and action to be taken and medical
conditions aggravated by exposure to benzene.
The care that must be taken whenever and wherever benzene is used, handled, stored
and transported.
Emergency procedures for leaks, spills, and fires, including protective clothing to be
worn in such instances.
The availability of written benzene usage, health hazard and training program
procedures.
The need for and the requirements of the medical surveillance program.
Samples may be taken through the manway opening by means of a clean, dry 1 -qt. (1-L)
bottle held in a clean, dry sheath of nickel or stainless steel attached to a long rod or
lightweight chain of the same material. Fit the bottle with a glass stopper to which is attached
a light metal chain. Lower the bottle to near the bottom of the tank and pull out the stopper
with a sharp jerk of the chain. Raise it at such a rate that it is about three fourths full when it
emerges from the liquid. Emphasis should be placed on cleanliness and dryness. Both the
sample bottle and its holder must be clean and dry. Transfer the sample to another bottle for
Page 44
storage. A suitable bottle for storing the sample is one known as a Boston Round. The
closure should be a screw cap with Teflon or aluminium foil liner.
9.1.2 Storage and Transportation
Internal floating roof storage tanks are recommended for the bulk storage of benzene. Storage
tanks should be designed to eliminate fugitive emissions. A rule of thumb commonly used for
determining the size of customer storage facilities suggests that storage facilities be 1 times
the size of shipments received. Some facilities may require larger inventories because of
seasonal transportation problems. We can primarily assume that storage tank of capacity
5000m3 is sufficient for the plant. It must have solid foundation. Benzene is usually stored as
a liquid at temperatures above 46 F (8C) to avoid freezing. Liquid benzene can be
transferred by pump or vacuum. For most benzene handling, centrifugal pumps with
mechanical seals perform satisfactorily.
The following are recommended practices in engineering pipelines for benzene.
A minimum of flanged connections should be used on benzene pipelines. Flanges

should be avoided due to leak potential.
Benzene lines should not be buried because of the difficulty of checking for leakage.
All lines carrying benzene should be sloped so that they can be completely drained for
maintenance.
All newly installed benzene pipelines should be pressure-tested by an approved

method before insulation is applied.
Bellows valves for 2 inch and smaller are recommended to eliminate emissions from
packing.
9.2 Propylene
9.2.1 Safety
Protective footwear, clothing, respiratory systems, glasses are recommended while
dealing with propylene. Gas detectors are also required to detect leakages.
9.2.2 Storage and Handling
There are two basic types of vessels used to store propylene: pressurized or cylindrical
(bullet tanks) and spherical storage tanks. Liquid propylene can be stored in spheres at
Page 45
atmospheric pressure, up to 2.5 psig and fully refrigerated; the normal boiling point of
propylene is 54F. For smaller capacities, propylene can be stored at atmospheric
temperature, but in fully pressurized containers (spheres). Spherical tank gives extra
stability to the storage. Its speciality is exerting equal pressure in all directions. But its
construction cost is more, so sometimes bullets are preferred.
Carbon steel is suitable material of construction in most of the cases. But when storage
temperature is expected below -50C stainless steel is used. All vessel types must have a
foundation suitable for the tank design. They are generally constructed from concrete or
steel and are designed to transmit all loads to the earth. When the support is constructed
from steel, it should be protected from fire exposure.
Storage vessels should be protected against overpressure, under pressure and overfilling
by means such as a reliable level-indicating device, an independent high-level alarm, a
high-level cutoff, overpressure relief valves and vacuum relief. The set point for
overpressure relief valves should not exceed the maximum allowable working pressure
(MAWP) of the storage vessel, or the vessel may rupture in the event of high pressure.
Double wall tanks have overpressure protection on both the inner storage area and the
annular space between the walls.
9.3 Cumene
9.3.1 Safety
Respiratory Protection: Use appropriate NIOSH approved respirators in accordance

with 29 CFR 1910.132 and 1910.134, to prevent overexposure. Respirators must be
selected based on the airborne levels found in the workplace and must not exceed the
working limits of the respirator.
Eye Protection: Use splash proof chemical safety goggles or appropriate full-face
respirator. Follow the eye and face protection guidelines of 29 CFR 1910.132 and
1910.133. Where there is any possibility that an individual's eyes may be exposed to
isopropylbenzene, an eye wash fountain (in accordance with 29 CFR 1910.151)
should be within the immediate work area for emergency use.
Protective Gloves: Use gloves in accordance with 29 CFR 1910.132 and 29 CFR
1910.138.
Page 46
Ventilation:
Provide local ventilation to maintain exposure levels below
recommended exposure limits, and to prevent accumulation of isopropylbenzene in

explosive levels. Use explosion proof ventilation equipment. Local exhaust
ventilation should comply with OSHA regulations and the American Conference of
Governmental Industrial Hygienists, Industrial Ventilation - A Manual of
Recommended Practice.
Exposure Guidelines: The OSHA-PEL, NIOSH-REL and ACGIH-TLV for

Isopropylbenzene [Cumene] is 50 ppm (8-hr TWA). The IDLH is 900 ppm [10%
LEL].
Other: Where there is a possibility of exposure of an individual's body to

isopropylbenzene, facilities for quick drenching of the body should be provided (in
accordance with 29 CFR 1910.151) within the immediate work area for emergency
use. Such individuals should be provided with and required to use impervious
clothing in accordance with 29 CFR 1910.132.
9.3.2. Storage and Handling

Store in a well ventilated place away from sources of ignition, and oxidizing agents and in
accordance with 29 CFR 1910.106. Store in metal containers. Ground and bond all
storage and transfer equipment to prevent possible ignition from static sparks. Use spark
resistant equipment (tools) in the isopropylbenzene area. Store in an area equipped with
automatic sprinklers or fire extinguishing system. Wear appropriate protective equipment
when handling isopropylbenzene. All seals, gaskets, liners and other such parts exposed
to isopropylbenzene service should be made of aromatic resistant elastomers. Do not use
rubber- lined tanks. Since emptied containers retain product residues, assume emptied
containers to have the same hazards as full containers. Follow all federal, state and local
regulations as well as all insurance codes when storing and handling isopropylbenzene.
Page 47
CHAPTER-10
LINE SIZING
10.1 Algorithm
I.
Initial diameter estimate10.1

w= mass flow rate
Use largest diameter in mm for the rest of calculation.
II.
Calculate Reynolds number10.2
III.
From graph calculate friction factorFigure
Figure 10.1 Friction Factor Curve

Effective roughness for the given material needs to be taken from Perrys Handbook.
IV.
Calculate frictional Pressure loss10.3
V.
Calculate Velocity10.4
Page 48
VI.
Repeat the procedure by estimating different diameter until the pressure drop
(allowable) and velocity limitations are met.
10.2 Pipe Length Estimations

Table 10.1 Pipe lengths estimate for line sizing
All the values have unit meters
Benzene
Support
Height
Distance up
to Pipe rack
Height of
Pipe rack
Length on
pipe rack
Height of
Pipe rack
Distance till
equipment
support
height of
equipment
Additional
Propane
Recycle
benzene
Cumene
0.3048
0.3048
0.3048
0.3048
10
10
10
10
4.9
4.9
50
50.1
60
75
40
4.9
4.9
15
14.9
15
15
17
Ts no.
Bends no.
height of top
product
Total
Length
Propylene
11
11
12
12
7
92.3048
92.3048
109.1048
7
117.1048
76
Page 49
CONCLUSION
Page 50
REFERENCES
[1] Alexander C, Dimilan and Costin Sorin Bildea, Chemical Process Design:
Computer aided Design
[2] Alkylation licensing; retrieved from www.exxonmobilchemical.com/Chemenglish/alkylation-licensing.aspx On date 26/10/2014
[3] Chung ming chi, Dana E Johnson, Joseph Peters, Kevin J , Process for
Producing Cumene, retrieved from, www.google.com./patents/EP2342170A1. On
date 6/12/2014
[4] Fogler S, Elements of Chemical Reaction Engineering, 4 th ed, PHI Learning
pvt ltd.(2006)
[5] KLM technology group, Layout and Spacing ( Project Standards and
Specifications) Feb 2011.
[6] Mahajani VV, Umarji SB, Joshis Process Equipment Design, fourth edition
Mcmillan Publishers India Ltd (2009)
[7] Mahapatra Nirlipt, Design and Simulation of cumene plant using ASPEN Plus
simulator, retrieved from ethesis.nitrkl.ac.in/1746/1/nirlipt.pdf
[8] McCabe, W L., Smith, J. C., Harriott, P., Unit Operations of Chemical
Engineering, Sixth Edition, McGraw-Hill Higher Education (2001).
[9] Peters M, Timmerhaus K, Plant Design and Economics for chemical
engineers, 4th ed, McGraw Hill Publications.
[10] SB Thakore, BI Bhatt, Introduction to Process Engineering and Design,
McGraw Hill Publications.
[11] Treybal R, Mass Transfer Operations, 3 rd ed, Tata-McGraw Hill Publications.
[12] Turton, R, Bailie RC, Whitting WB, Shaelwitz JA, Analysis, Synthesis and
Design of Chemical Processes, 2nd ed.; Prentice Hall: Upper Saddle River, NJ,
2003.
Page 51
[13] www.uop.com/cumene-qmax/ UOP Q-Max Cumene Process. On date

26/10/2014
[14] www.engyd.blogspot.in/2009/09/; Cumene flow sheets. On date 6/12/2014
[15] www.che.cemr.wvu.edu/publications/projects; Design thesis guidelines, West
Virginia University. On date 24/10/2014
[16] www.sciencelab.com/msds.php
Material safety data sheet. On date
5/12/2014
[17] www.owlnet.rice.edu/-ceng403/hysys/intro
Introduction to simulation of
reactor. On date 10/2/2015
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To design cumene manufacturing process manually.

To carry out chemical engineering calculation using MS EXCEL.

Dr. Babasaheb Ambedkar Technological University, Lonere

Design and Simulation of Cumene Manufacturing Process

Figure 2.1 Acid Catalyst Processes

Design and Simulation of Cumene Manufacturing Process

Figure 2.2. Aluminium chloride catalyst

Design and Simulation of Cumene Manufacturing Process

and Badger named beta

Dr. Babasaheb Ambedkar Technological University, Lonere

Design and Simulation of Cumene Manufacturing Process

Figure 2.3 Exxonmobil process

Design and Simulation of Cumene Manufacturing Process

Mobil/Badger[2] cumene technology licensed by Badger Licensing, are able to operate at

Figure 2.4 Q-Max processes

Design and Simulation of Cumene Manufacturing Process

Design and Simulation of Cumene Manufacturing Process

reactions involved include isomerisation and dis-proportionation. The reaction mechanism as

Dr. Babasaheb Ambedkar Technological University, Lonere

Design and Simulation of Cumene Manufacturing Process

Isomerisation [5] [1]

Transalkylation [5] [1]

Design and Simulation of Cumene Manufacturing Process

Non-corrosive in presence of glass.

Dr. Babasaheb Ambedkar Technological University, Lonere

Design and Simulation of Cumene Manufacturing Process

Very slightly soluble in cold water.

The substance is toxic to lungs, the

Very hazardous in case of skin

Dr. Babasaheb Ambedkar Technological University, Lonere

Design and Simulation of Cumene Manufacturing Process

Clear colourless, colourless to light yellow

Miscible in alcohol, chloroform,

tetrachloride, glacial acetic acid,

Stability and reactivity

Very slightly soluble in water.

Benzene vapours + Chlorine and

Highly reactive with oxidizing

Design and Simulation of Cumene Manufacturing Process

Table 2.3 Material Safety Data Sheet for Propylene [14]

Stability and reactivity

Soluble in alcohol, ether, acetic

May react on contact with air, heat,

Dr. Babasaheb Ambedkar Technological University, Lonere

Design and Simulation of Cumene Manufacturing Process

Dr. Babasaheb Ambedkar Technological University, Lonere

Design and Simulation of Cumene Manufacturing Process

tons per day of cumene.

kg of cumene per hr.

)/120.19 Kmoles of cumene per hr.

Dr. Babasaheb Ambedkar Technological University, Lonere

Design and Simulation of Cumene Manufacturing Process

Cumene =12626.26 Kg/hr

Benzene in product = 135.375-105.05 = 30.37145 Kmoles/hr

Design and Simulation of Cumene Manufacturing Process

F = Benzene + Cumene =15131.99Kg/hr

D = Benzene =1593.602 Kg/hr

Dr. Babasaheb Ambedkar Technological University, Lonere

Design and Simulation of Cumene Manufacturing Process

Product cumene outflow

Table 3.2 Overall material balance ExcelSheet