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CHAPTER I

INTRODUCTION AND ITS BACKGROUND

The petrochemical process industry is mainly involved in manufacturing of

wide range of products which improves the quality of life of humankind and

generates employment. Engineers deal with a lot of obstacles while designing a

process especially when substances involved have high chemical reactivity, high

toxicity, and high corrosivity operating at high pressures and temperatures.

Ethylbenzene is an organic chemical compound which is an aromatic

hydrocarbon. Its major use is in the petrochemical industry as an intermediate

compound for the production of styrene, which in turn is used for making

polystyrene, a commonly used plastic material.

Although often present in small amounts in crude oil, ethyl benzene is

produced in bulk quantities by combining the petrochemicals benzene and

ethylene in an acid-catalyzed chemical reaction. Catalytic hydrogenation of the

ethyl benzene then gives hydrogen gas and styrene, which is vinyl benzene. Ethyl

benzene is also an ingredient in some paints. Ethylbenzene is used almost

exclusively as intermediate in the production of styrene monomer. The main target

of designing this plant is to manufacture a chemical product in a stable and

economical manner.

Ethylbenzene is produced by the catalytic alkylation of benzene with

ethylene, or from mixed xylenes by isomer separation and catalytic isomerization,

or from 1,3-butadiene in a two-step process where the butadiene is converted to

vinyl cyclohexane which is then dehydrogenated. Nearly all commercial


ethylbenzene is produced by alkylation of benzene with ethylene. Earlier

processes were based on liquid phase alkylation using an aluminum chloride

catalyst but this route required disposal of aluminum chloride waste.

A major difficulty faced during manufacturing of EB is that ethyl benzene is

more reactive compared to benzene with respect to ethylene due to lower

activation energy and thus it leads to the formation of diethylbenzenes. To limit the

formation of DEBs and other polyethylbenzene, we use a large excess ratio of

Benzene to Ethylene in the feed to the alkylation reactor. However, large excess

ratio leads to higher equipment, separation and recycle cost.

There are primarily two sources to produce ethylbenzene. The major being

alkylation of benzene and other being super fractionation of C8 aromatic streams.

Alkylation of benzene in liquid phase using aluminum chloride as catalyst is the

most used method for ethylbenzene production. Different companies like Shell,

Union Carbide and Dow use this method.

Earlier vapor phase alkylation were not able to compete with liquid phase

alkylation. The alkylation process using boron trifluoride as catalyst had little

success and suffered drawbacks like high maintenance costs caused by corrosion

from small amount of water. Zeolites were used earlier for alkylation process but

they deactivated quickly because of coke formation and low catalytic activity.

Ethylbenzene Properties

Melting Point -95 C

Boiling point 136 C

Density 0.867 g/ml at 25C


Vapor Density 3.7

Vapor Pressure 28.69psi

Refractive Index N20/D 1.495

Flash Point 72F

Storage Temperature 0-6C

Solubility 0.2g/l

Form Liquid

Color Colorless

Relatiive Polarity 0.117

Odor Aromatic

Explosive Limit 1.0-7.8%

Water Solubility 0.0206g/100ml

Freezing Point -95C

Ethylene Properties

Formula C2H4

Molecular Weight 28.05 lb/mol

Critical Temperature 49.1F

Critical Pressure 742.7 psia

Boiling Point -154.8F

Melting Point -272.5


Gas Density 0.0730 lb/ft3

Specific Volume 13.70 ft3/lb

Specific Gravity 0.992

Specific Heat 10.28

Benzene Properties

Molar Mass 78.1118

Critical Temperature 562.02 K

Critical Pressure 4.894mpa

Criticsl Density 3.902

Triple Point Temperature 278.67 K

Reference Temperature 353.21635

Reference Pressure 0.101325 Mpa K

Location

The location that the proponents have decided is at Brgy. Alas Asin,

Mariveles, Bataan. This is selected since the raw materials of the proposed plant

is from Petron Corporation in Limay, Bataan. Also, it is accessible since it is located

beside the national road and is also located near the waters. The figure shows the

exact location of the proposed plant.


This site is considered a feasible zone for the construction as proven by the

factors discussed in the next sections:

1. Raw Material Availability

“Petron Corporation is the largest oil refining and marketing company in

the Philippines and is a leading player in the Malaysian market. The

reformer uses a catalyst to increase the octane number of naphtha while

producing LPG, gasoline, and reformate. Meanwhile, reformate is

further converted to become petrochemical feedstocks benzene,


toluene, and mixed xylene. To be specific, Petron Corporation in Bataan

produces over 50000 MT of benzene annually which will be sufficient for

the feedstock needed for the production of ethylbenzene.

2. Water Source

Since coolers are located all around the plant which uses water streams,

a nearby water source is needed. Output of the alkylator reactor mixed

that of the transalkylator and the combined stream will pass through a

cooler, and also a vapor stream from the separator which will go through

a compressor to increase stream pressure to column pressure will also

need a cooler to reduce temperature which rose due to compression.

3. Transportation Facilities

Brgy. Alas Asin is a strategic place since it is located near the national

road and is near transport facilities like Seasia Nectar Port Services and

others. It is also near Petron Corporation and will make the

transportation of the required feed benzene easier and safer.

Raw Material

Petron Corporation is the largest oil refining and marketing company in the

Philippines and is a leading player in the Malaysian market. The reformer uses a

catalyst to increase the octane number of naphtha while producing LPG, gasoline,

and reformate. Meanwhile, reformate is further converted to become

petrochemical feedstocks benzene, toluene, and mixed xylene. To be specific,

Petron Corporation in Bataan produces over 50000 MT of benzene annually which

will be sufficient for the feedstock needed for the production of ethylbenzene.
Product

Ethylbenzene is an organic compound with the formula C6H5CH2CH3. It is a

highly flammable, colorless liquid with an odor similar to that of gasoline. This

monocyclic aromatic hydrocarbon is important in the petrochemical industry as an

intermediate in the production of styrene, the precursor to polystyrene, a

common plastic material. In 2012, more than 99% of ethylbenzene produced was

consumed in the production of styrene.

The greatest use, more than 99 percent of ethylbenzene, is to make

styrene, another organic liquid used as a building block for many plastics. It is also

used as a solvent for coatings, and in the making of rubber and plastic wrap. Much

smaller amounts of ethylbenzene are used in solvents or as additives to a variety

of products. Some products that contain ethylbenzene include synthetic rubber,

gasoline and other fuels, paints and varnishes, inks, carpet glues, tobacco

products, and insecticides. Ethylbenzene finds wide application as solvent and

reagent in producing various products, such as paints & coatings, dyes, varnishes,

lacquers, adhesives, rust prevention spray, pharmaceuticals, cleaning materials,

dyes, inks, perfumes, synthetic rubber, plastics, and pesticides.

Demand

The increasing construction activities, particularly in Asia-Pacific, the rising

automotive production, driven by increasing demand for SUV’s and electric

vehicles, and the growth in pharmaceutical industry is driving the ethylbenzene

demand for application as a solvent and reagents in producing paints & coatings,

varnishes, adhesives, rust prevention sprays, etc., used in these industries.


Ethylbenzene is majorly used for the production of styrene, which is a

precursor to various industrial polymers, such as polystyrene, acrylonitrile-

butadiene-styrene, styrene-acrylonitrile resins, styrene-butadiene elastomers and

latex, and unsaturated polyester. These styrene-based polymers, resins, and

elastomers find wide application in various end-user industries, such as packaging,

electronics, construction, agriculture, and petrochemicals. Thus, a strong growth

in the aforementioned end-user industries is driving the demand for styrene

products, further leading to an increase in the demand for ethylbenzene in order

to produce styrene.

Global ethylbenzene production grew to 31.6 million tons in 2018, with the

largest application being the production of styrene. Increased demand has been

driven by investment in downstream derivatives in the Middle East and China. With

new global capacity, demand growth of 1.98 percent per year is expected through

2025.

Target Market

Automotive. Ethylbenzene has been added to motor and aviation fuels

because of its anti-knock properties. Estimates of ethylbenzene in gasoline have

ranged from < 1–2.7%

Chemicals. It is also used to make other chemicals, including

acetophenone, cellulose acetate, diethyl-benzene, ethyl anthraquinone,

ethylbenzene sulfonic acids, propylene oxide, and alpha-methylbenzyl alcohol.


Electroplating. Ethylbenzene is one of the most commonly used solvent

during electroplating which is a uses an electric current to reduce dissolved metal

cations so that they form a thin coherent metal coating on an electrode.

Paint Manufacturers. Ethylbenzene is added to gasoline as an anti-knock

agent, meaning it reduces engine knocking and increase the octane rating.

Plastic Manufacturers. Styrene is produced predominately by

ethylbenzene. It is a chemical used to make latex, synthetic rubber, and

polystyrene resins. These resins are used to make plastic packaging, disposable

cups and containers.


CHAPTER II

DESIGN OBJECTIVES AND REQUIREMENTS

The main objective of the study is to design an Ethylbenzene Production

Plant which makes use of ethylene and benzene as the raw materials for the

manufacturing. For the development of the desired plant, the following specific

objectives must be met:

1. Present and analyze three design alternatives of the proposed

Ethylbenzene Production Plant to determine the design trade-offs of the

design options:

1.1. Single distillation column configuration

1.2. Multiple distillation column configuration

1.3. Multiple distillation column configuration with thermal cracking

2. Conform to the technical specifications of the equipment to be used in the

design from the following required standards:

2.1. ISO

2.2. Other Standards

3. Perform economic analysis of the plant to determine the most economically

efficient or cost – effective choice among the design alternatives by

determining the following:

3.1. Rate of Return

3.2. Payback Period

3.3. Net Present Value


4. Construct a Project Construction Execution Plan after evaluating and

selecting the best design option from the alternatives.

5. Present a simulation video of the whole production plant from the best

design option highlighting the plant layout and processes


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

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

Distillation Column

“ Distillation columns are usually tall structures filled with heated

flammable fluids, and are consequently inherently hazardous. The column

is divided into a number of horizontal sections by metal trays or plates, and

each is the equivalent of a still. The more trays, the more redistillation, and

hence the better is the fractionation or separation of the mixture fed into the

tower. Distillation columns are key unit operations in traditional chemical

engineering, especially in the oil and gas industry. ”

Distillation Column Specifications

No. of Trays 35 – 40

Temperature Up to 140oC
Pressure Up to 17 bars

Tray Type Sieve

Tray Material Stainless Steel 316

Column Material Carbon Steel

Separator

It is a device which separates a fluid into its constituent components.

Liquid removed by the inlet diverter falls to the bottom of the vessel. The

gas moves upward, usually passing through a mist extractor to remove

suspended mist, and then flows out. Liquid removed by the mist extraction

is coalesced into larger droplets that fall down to the liquid reservoir in the

bottom. Mist extractors can significantly reduce the required diameter of

vertical separators. Horizontal separators are most efficient for large

volumes of total fluids and when large amounts of dissolved gas are present
with the liquid. The greater liquid surface area provides optimum conditions

for releasing gas from liquid.

Separator Specifications

Temperature Up to 40oC

Pressure Up to 19 bars

Construction Material Carbon Steel

Alkylation Reactor

In the alkylation reactor, the introduction of an alkykl group into an

organic compound by substitution or addition takes place. There are six

types of alkylation reaction such as substitution for hydrogen bound to

carbon, such as ethylbenzene and benzene and ethylene substitution for

hydrogen attached to nitrogen, substitution for hydrogen in a hydroxyl group


of an alchol or phenol, and addition to atertiart amine to form a quaternary

ammonium compound. Other major alkylation products include

ethylbenzene and linear alkylbenzene derivatives.

Transalkylation Reactor

Transalkylation reactor is used for chemical reaction involving the

transfer of an alkyl group from one compound to another. The reaction is

used for the transfer of methyl and ethyl between benzene rings. It is often

combined with alkylation in order to convert low valued by-products such as

polyalkylbenzenes into their monosubstituted homologoues, globally

improving the efficiency of the process.

d. 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

 Fire Brigade

 Guard House

 Jetty

 Parking Lot

 Power Room

 Process Area

 Tank Farm

 Wastewater Treatment Facility


e. 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.


f. 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 + m2 +m13 = m3

m1 m1 = 13,682.954 kg/hr

m13 M-101 m3 m2 = 2943.493 kg/hr 100%

m2 m13 = 46,994.144 kg/hr

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 = 61,428.306 kg/hr

m4 m14 = 283.667 kg/hr 99%

D-101 m5 m5 = 61,094.853 kg/hr

m14

m5 = 61,094.853 kg/hr

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

m5 S-101 m6 = 208.942 kg/hr 99%

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 kg/hr


m13 = (m12)(0.97)(0.994)

m13 m13 = 46,994.144 kg/hr 97%

m12 u
R-102 m14 = (m12)(0.97)(0.006)

m14 m14 = 283.667 kg/hr

g. 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 = (48,570.008 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

Q8 = (48,570.008 kg)(1.066 kJ/kg.K)

(303.15 K – 298.15 K)

Q8 = 258,878.153 kJ

Q8 Q11 = (170.003 kg)(1.946 kJ/kg.K)

u
M-102 Q12 (303.15 K – 298.15 K)

Q11 Q11 = 1,654.129 kJ

Q12 = (48,740.011 kg)(1.068 kJ/kg.K)

(303.15 K – 298.15 K)

Q12 = 260,271.659 kJ

Q12 = (48,740.011 kg)(1.068 kJ/kg.K)

(453.15 K – 433.15 K)

Q12 u
R-102 Q13 Q12 = 1,041,086.63 kJ

Q13 = (47,277.811 kg/hr)(1.726 kJ/kg.K)


(453.15 K – 433.15 K)

Q13 = 1,632,030.04 kJ

Design Option 2

a. Process Design Layout

b. Process Description

It will be almost like the first design option. The only difference is that

in there will be only one distillation column where three products are made.

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 only distillation column

will separate the three components of the inlet mixture separately. The top

part will produce benzene, the middle will produce ethylbenzene, while the

bottom will produce diethylbenzene. The top and bottom products will be

mixed and be fed to 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.

c. Major Equipment and their Functions

Distillation Column

“ Distillation columns are usually tall structures filled with heated

flammable fluids, and are consequently inherently hazardous. The column

is divided into a number of horizontal sections by metal trays or plates, and

each is the equivalent of a still. The more trays, the more redistillation, and

hence the better is the fractionation or separation of the mixture fed into the
tower. Distillation columns are key unit operations in traditional chemical

engineering, especially in the oil and gas industry. ”

Distillation Column Specifications

No. of Trays 35 – 40

Temperature Up to 140oC

Pressure Up to 17 bars

Tray Type Sieve

Tray Material Stainless Steel 316

Column Material Carbon Steel


Separator

It is a device which separates a fluid into its constituent components.

Liquid removed by the inlet diverter falls to the bottom of the vessel. The

gas moves upward, usually passing through a mist extractor to remove

suspended mist, and then flows out. Liquid removed by the mist extraction

is coalesced into larger droplets that fall down to the liquid reservoir in the

bottom. Mist extractors can significantly reduce the required diameter of

vertical separators. Horizontal separators are most efficient for large

volumes of total fluids and when large amounts of dissolved gas are present

with the liquid. The greater liquid surface area provides optimum conditions

for releasing gas from liquid.

Separator Specifications

Temperature Up to 40oC
Pressure Up to 19 bars

Construction Material Carbon Steel

Alkylation Reactor

In the alkylation reactor, the introduction of an alkykl group into an

organic compound by substitution or addition takes place. There are six

types of alkylation reaction such as substitution for hydrogen bound to

carbon, such as ethylbenzene and benzene and ethylene substitution for

hydrogen attached to nitrogen, substitution for hydrogen in a hydroxyl group

of an alchol or phenol, and addition to atertiart amine to form a quaternary

ammonium compound. Other major alkylation products include

ethylbenzene and linear alkylbenzene derivatives.


Transalkylation Reactor

Transalkylation reactor is used for chemical reaction involving the

transfer of an alkyl group from one compound to another. The reaction is

used for the transfer of methyl and ethyl between benzene rings. It is often

combined with alkylation in order to convert low valued by-products such as

polyalkylbenzenes into their monosubstituted homologoues, globally

improving the efficiency of the process.

d. 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

 Fire Brigade

 Guard House

 Jetty

 Parking Lot

 Power Room

 Process Area

 Tank Farm

 Wastewater Treatment Facility


e. 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.


f. Material Balance and Calculations

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. It will

have a single distillation column configuration.

Diagram Calculation Efficiency

m1 m1 = 13,682.954 kg/hr

m13 M-101 m3 m2 = 2,745.342 kg/hr 100%

m2 m13 = 46,994.144 kg/hr

m16 m16 = 198.151 kg/hr

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 m4 = 61,428.306 kg/hr

D-101 m5 m14 = 283.667 kg/hr 99%

m14 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 99%

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 kg/hr

m13 m13 = (m12)(0.97)(0.994)

m12 u
R-102 m13 = 46,994.144 kg/hr 97%

m14 m14 = (m12)(0.97)(0.006)

m14 = 283.667 kg/hr


m6 = 208.492 kg/hr

m6 F-101 m15 m15 = (m6)(0.99) 99%

m15 = 206.407 kg/hr

m15 = 206.407 kg/hr

m15 u
C-103 m16 m16 = (m14)(0.97) 96%

m16 = 198.151 kg/hr

g. Energy Balance and Calculations

Design Option 3

a. Process Design Layout

b. Process Description

The difference of this process is that it includes a thermal cracking

process for the ethane from the separator, for it to evolve into ethylene and
be an additional feed. Aside from that, the process is pretty much similar to

the first design option.

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. Then, the separated ethane

will go through a furnace to pre-heat before entering the fractionating

column where it will be thermally cracked to form ethylene and serve as a

recycle to the feed.

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 Functions

Distillation Column

Distillation columns are usually tall structures filled with heated

flammable fluids, and are consequently inherently hazardous. The column

is divided into a number of horizontal sections by metal trays or plates, and


each is the equivalent of a still. The more trays, the more redistillation, and

hence the better is the fractionation or separation of the mixture fed into the

tower. Distillation columns are key unit operations in traditional chemical

engineering, especially in the oil and gas industry. ”

Distillation Column Specifications

No. of Trays 35 – 40

Temperature Up to 140oC

Pressure Up to 17 bars

Tray Type Sieve

Tray Material Stainless Steel 316

Column Material Carbon Steel

Separator
It is a device which separates a fluid into its constituent components.

Liquid removed by the inlet diverter falls to the bottom of the vessel. The

gas moves upward, usually passing through a mist extractor to remove

suspended mist, and then flows out. Liquid removed by the mist extraction

is coalesced into larger droplets that fall down to the liquid reservoir in the

bottom. Mist extractors can significantly reduce the required diameter of

vertical separators. Horizontal separators are most efficient for large

volumes of total fluids and when large amounts of dissolved gas are present

with the liquid. The greater liquid surface area provides optimum conditions

for releasing gas from liquid.

Separator Specifications

Temperature Up to 40oC

Pressure Up to 19 bars

Construction Material Carbon Steel

Alkylation Reactor

In the alkylation reactor, the introduction of an alkykl group into an

organic compound by substitution or addition takes place. There are six

types of alkylation reaction such as substitution for hydrogen bound to

carbon, such as ethylbenzene and benzene and ethylene substitution for

hydrogen attached to nitrogen, substitution for hydrogen in a hydroxyl group

of an alchol or phenol, and addition to atertiart amine to form a quaternary


ammonium compound. Other major alkylation products include

ethylbenzene and linear alkylbenzene derivatives.

Transalkylation Reactor

Transalkylation reactor is used for chemical reaction involving the

transfer of an alkyl group from one compound to another. The reaction is

used for the transfer of methyl and ethyl between benzene rings. It is often

combined with alkylation in order to convert low valued by-products such as

polyalkylbenzenes into their monosubstituted homologoues, globally

improving the efficiency of the process.

Furnace

Fractionator

d. Components of the Plant

e. Land Area

f. Material Balance and Calculations


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. Ethane

here will be reused by making it go through a thermal cracking process for

ethylene to evolve.

Diagram Calculation Efficiency

m1 m1 = 13,143.388 kg/hr

m12 M-101 m3 m2 = 2,808.426 kg/hr 100%

m2 m12 = 45,100.925 kg/hr

m3 = 61,052.739 kg/hr

m3 = 61,052.739 kg/hr

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

m4 = 59,221.157 kg/hr

m4 m4 = 58,945.132 kg/hr

D-101 m5 m13 = 276.239 kg/hr 99%

m13 m5 = 58,629.157 kg/hr

m5 = 58,629.157 kg/hr
m6 m6 = (m5)(0.99)(0.003)

m5 S-101 m6 = 174.129 kg/hr 99%

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

m7 = 57,868.737 kg/hr

m7 = 57,868.737 kg/hr

m8 = (m7)(0.96)(0.839)

m8 m8 = 46,609.796 kg/hr

m7 u
C-101 m9 m9 = (m7)(0.96)(0.158) 96%

m10 m9 = 8,777.530 kg/hr

m10 = (m7)(0.96)(0.003)

m10 = 166.662 kg/hr

m8 m8 = 46,609.796 kg/hr

u
M-102 m11 m10 = 166.662 kg/hr 100%

m10 m11 = 46,776.458 kg/hr

m11 = 46,776.458 kg/hr

m12 m12 = (m12)(0.97)(0.994)

m11 u
R-102 m12 = 45,100.925 kg/hr 97%

m13 m13 = (m12)(0.97)(0.006)

m13 = 272.239 kg/hr

g. Energy Balance and Calculations

Diagram Calculation

Q1 = (58,244.313 kg/hr)(1.066 kJ/kg.K)


(303.15 K – 298.15 K)

Q1 = 310,442.188 kJ

Q1 Q2 = (2,808.426 kg)(1.55 kJ/kg.K)

M-101 Q3 (303.15 K – 298.15 K)

Q2 Q2 = 21,765.302 kJ

Q3 = (61,052.739 kg)(1.09 kJ/kg.K)

(303.15 K – 298.15 K)

Q3 = 332,737.428 kJ

Q3 = (61,052.739 kg)(1.09 kJ/kg.K)

(403.15 K – 333.15 K)

Q3 R-101 Q4 Q3 = 4,658,323.986 kJ

Q4 = (59,221.157 kg)(1.12 kJ/kg.K)

(403.15 K – 333.15 K)

Q4 = 4,642,938.709 kJ

Q4 = (59,221.157 kg)(1.12 kJ/kg.K)

(328.15 K – 313.15 K)

Q4 D-101 Q5 Q4 = 994,915.438 kJ

Q5 = (58,629.157 kg)(1.12 kJ/kg.K)

(328.15 K – 313.15 K)

Q5 = 984,969.838 kJ

Q5 = (58,629.157 kg)(1.12 kJ/kg.K)

(333.15 K – 313.15 K)

Q5 = 1,313,293.117 kJ
Q6 Q6 = (174.129 kg)(1.766 kJ/kg.K)

Q5 S-101 (333.15 K – 313.15 K)

Q7 Q6 = 6,150.236 kJ

Q7 = (57,868.737 kg)(1.15 kJ/kg.K)

(333.15 K – 313.15 K)

Q7 = 1,330,980.951 kJ

Q7 = (57,888.737 kg)(1.15 kJ/kg.K)

(413.15 K – 328.15 K)

Q7 = 5,658,624.042 kJ

Q8 = (46,609.796 kg)(1.066 kJ/kg.K)

Q8 (413.15 K – 328.15 K)

Q7 C-101 Q9 Q8 = 4,223,313.616 kJ

Q10 Q9 = (8,777.530 kg)(1.726 kJ/kg.K)

(413.15 K – 328.15 K)

Q9 = 1,287,751.426 kJ

Q10 = (166.662 kg)(1.946 kJ/kg.K)

(413.15 K – 328.15 K)

Q10 = 27,567.561 kJ

Q8 = (46,609.796 kg)(1.066 kJ/kg.K)

(303.15 K – 298.15 K)

Q8 = 248,430.213 kJ

Q8 Q10 = (170.003 kg)(1.946 kJ/kg.K)

u
M-102 Q11 (303.15 K – 298.15 K)
Q10 Q10 = 1,654.129 kJ

Q11 = (48,740.011 kg)(1.068 kJ/kg.K)

(303.15 K – 298.15 K)

Q11b = 260,271.659 kJ

Q12 = (48,740.011 kg)(1.068 kJ/kg.K)

(453.15 K – 433.15 K)

Q12 u
R-102 Q13 Q12 = 1,041,086.63 kJ

Q13 = (47,277.811 kg/hr)(1.726 kJ/kg.K)

(453.15 K – 433.15 K)

Q13 = 1,632,030.04 kJ

CHAPTER V

ENVIRONMENTAL MANAGEMENT OF THE PROJECT

This chapter includes the environmental and health impacts, and safety

precautions of Ethylbenzene Production Plant as well as the possible mitigation

accomplish to complete the plant design.


The three design options’ variances of the Ethylbenzene Production Plant

are negligible. Therefore, the following attentions will apply to all three design

options. Moreover, the considerable variances among these designs are

emphasized and summarized in the final part of this chapter for the purpose of

selecting the best design option considering the numerous environmental factors.

I. Environmental Impacts

The Environmental Impact Assessment (EIA) is known to clearly rate

and assess the possible effects of the development of Ethylbenzene

Production Plant on land, water, atmospheric environment, human

environment and the ecology. More so, the EIA also checks the effects on

the environment of the construction, operational phases and utilities of the

plant.

Ethylbenzene is widely distributed in the environment principally due

to its use as a solvent alone and as a component of mixed xylenes, and as

a fuel additive, generally at very low levels in both ambient and indoor air,

water, sediment soil and biota. Large quantities have been emitted during

its production, use and disposal. The highest levels of ethylbenzene found

in the environment are often associated with industrial operations, and it is

one of the most commonly found substances at hazardous waste sites.

a. AIR

Ethylbenzene is ubiquitous in urban and rural atmospheres, resulting

primarily from vehicle, petroleum and industrial emissions. Because of its


high vapour pressure and low solubility, released ethylbenzene will disperse

into the atmosphere.

b. Water

Ethylbenzene, usually at < 1 μg/L, is found only infrequently in

drinking water from ground or surface sources. The levels of ethylbenzene

in surface water are generally less than 0.1 μg/L in non-industrial areas. In

industrial and urban areas, concentrations of up to 15 μg/L ethylbenzene

have been reported.

c. Soil and sediments

Ethylbenzene can be released to soils from a variety of sources,

including spillage of gasoline and other fuels, leaching from landfill sites and

disposal of solvents and household products such as paint, cleaning and

degreasing solvents, varnishes and pesticides.

d. Geology

The Ethylbenzene Production Plant is located in Brgy. Alas Asin,

Mariveles, Bataan. The area is surrounded with great biodiversity and also

near to bodies of water. Also, some of the projects in the vicinity is related

to the industry like Petron Corporation in Limay, Bataan. With that, the

location of the plant is clearly allocated for industrial development and thus

does not have negative effect to the geology.

e. Noise

The impact of the major noise sources on the work environment at a

production plant is minimal. Furnaces, gas turbines and steam turbo


generators, switching stations, and transformers are operated remotely.

During periodic inspections, personnel are required to wear ear protection

devices in high noise areas. These devices take the form of ear plugs, ear

muffs and hard hat-ear muffs which do not hamper employee’s work in any

manner. A modernized noise prediction model will be performed to enable

to know and anticipate the noise that comes from the facilities used in the

plant.

II. Health and Safety

In humans, eye irritation was observed after exposure to 10,000 ppm

ethylbenzene for a few seconds. Irritation and chest constriction after acute-

duration exposures to 2,000 ppm ethylbenzene. These symptoms

worsened as the concentration was increased to 5,000 ppm. Human

exposures in the range of 2,000–5,000 ppm ethylbenzene were associated

with dizziness and vertigo. Complete recovery occurs if exposure is not

prolonged. Momentary ocular irritation, a burning sensation, and profuse

lacrimation are observe in humans exposed to 1,000 ppm ethylbenzene.

Workers exposed occupationally to solvent mixtures that included

ethylbenzene shows an increased incidence of hearing loss compared to

unexposed individuals. Respiratory effects are not observed in exposed to

55.3 ppm ethylbenzene for 15 minutes. An increase in the mean number of

lymphocytes and a decrease in hemoglobin levels are observed during a 1-

year exposed chronically to solvents including ethylbenzene. However, no


adverse hematological effects are observed in workers exposed to

ethylbenzene for 20 years.

Process Safety Documentation

The process safety information should include chemical hazard

documentation and information on each of the critical pieces of equipment

with safe flammability, pressure, temperature, and material flow ranges.

Workers in this process should be instructed in the methods of safely

handling each of the chemicals involved. They should also have access to

documentation on initial startup, normal startup, and emergency operations.

A hazard analysis should be conducted to determine the extent to which a

process hazard could spread, the number of workers who would potentially

be affected, and the control and detection methods that could be

implemented to prevent the hazard.

Following this, appropriate safework practices must be implemented

to ensure the safety of workers on the process, including employee training

and safety and protection systems in the event of exposure to hazardous

chemicals and controls to prevent exposure. The process layout must

include access for emergency and maintenance vehicles in the event of an

emergency. Furthermore, space must be available around each individual

unit for repair and accessibility. A central control room must be implemented

to control the process units in each section. The room should have positive

pressure to prevent toxins from entering, and should be located in a region

that minimizes the risk of hazard to employees. Storage tanks should be


classified as above-ground storage tankage, separated from the process

units, and located downwind to minimize the likelihood of ignition in the

event of a leak. Tank inspection and 52 cleaning protocols should be

implemented to prevent worker exposure to toxic chemicals.

Mitigation Measures

In order to sustain the effectiveness and cleanliness of the proposed plant, the

management should keep their environment clean and uncontaminated. They should be

prepared for rules and mitigation for safe production.

A. Hazard Prevention and Control

The management of the plant ensures that the worksite and all

machinery is cared for properly so that the environment remains safe

and healthy. If maintenance needs exceed the capability of the worksite

employees, contract employees are hired to do the work and are

screened and supervised to ensure they work according to the site‘s

safety and health procedures. All employees, including all levels of

management, are held accountable for obeying site safety and health

rules.

B. Medical Services

The company provides medical care, travel medicines,

immunizations and medical equipment for the employees and to its near

residences.
C. Personal Protective Equipment

Accidents happen where the consequences for those involved

become unnecessarily extensive, for example as a result of the injured

person wearing the incorrect personal protective equipment – or no

protective equipment at all. More often than not, these are burn injuries.

Basic personal protective equipment (PPE) were provided to each of the

employees of the plant to minimize exposure to serious workplace

injuries and illnesses. PPE program is also implemented to address the

hazards present; the selection, maintenance, and use of PPE; the

training of employees; and monitoring of the program to ensure its

ongoing effectiveness.

D. Security

Security Personnel (security guards) are available in the plant,

and for extensive security purposes, Closed Circuit Television Cameras

(CCTV) surrounds every corner of the plant, from the entry point, control

room, processing area, and up to the exit point. These would make sure

the plant and every worker are secure and safe from work enabling them

to work with no worries in their mind.

E. Workplace Inspection

The company conducts monitoring and inspections to prevent

injuries and illnesses and equipment failure in the power plant. A


thorough examination of the workplace and equipment can identify

hazards present and to set a corrective action to minimize or remove the

hazard present in the workplace. This improves the safety of the

employees.

F. Fire Drill

The company conducts an emergency fire procedure once a

month. This emergency procedure trains the employees what to be done

in case of fire, practicing the evacuation of a building if there is ever a

fire, smoke, carbon monoxide or other emergency in the plant. The

company gives emergency plan procedures for handling sudden or

unexpected situations that improves the safety of employees.

Waste

Wastes with potential impacts on the environment will be treated with most

recent technology available in accordance with the relevant national and

international legal framework. The positive impacts that will be benefited from the

project are basically the additional material availability and reliability in the region

which is currently experiencing frequent shortages. The impact of reliability will

improve infrastructural conditions for further investments, basically related to the

chemical sector, in the area. Accordingly, this will enable increased employment

opportunities to the businesses in the area and hence help to improve the social

wellbeing also with improved life standards due to satisfactory electricity supply.

a. Process and Waste Water Treatment:


A waste treatment facility for treating wastewater from sewer is extremely

important for both environmental and safety reasons. Rainwater run off, waste

water, process water, and sewage from the plant that to be installed must all be

specially treated. Dumping this into a municipal sewer without treatment might

cause serious illnesses and its illegal. Process water used for heating and cooling

must be treated before release into the environment. This includes temperatures

and concentrations. One hazard associated with oily water sewers is H2S release.

Hot process water containing dissolved H2S enters the sewer system, and as the

temperature drops, H2S gas is released as a result of a decrease in solubility. This

can poison plant employees and release into the environment. Design must take

this into consideration.

Socio- Economic Benefits for each design

This section presents the socio- economic benefits of the project for each

design option including the social, political and ethical considerations.

A. Design Option I

Design option I is a production plant of ethylbenzene from raw

material ethylene and benzene. The plant will have the alkylation process

throughout the production. The socio-economic benefits of the proposed

plant will be the good quality ethylbenzene which will be purchased by

Filipino consumers especially plastic manufacturing companies. It will give

off various jobs to the target place residence.

B. Design Option II
Design Option II is a Ethylbenzene Production Plant with

Fractionator for thermal cracking process.

This plant model involves alkylation process with cracking which

upgrade very heavy fractions or to produce light fractions or distillates. It will

be efficient to use since there is addition to the process of production.

C. Design Option III

Design Option III is an Ethylbenzene Production Plant with only one

distillation column which has three end product. It gives more efficient

process in a low cost management. Having a single distillation column

eliminates the risk of leakage and lower the toxic air emissions.

Social, Political, and Ethical Considerations

Strategic decisions have the potential to impact the society and the people

around it. Decisions based on discretionary choices such volunteerism and charity

works are great contributors to social responsibility.

Decisions are always supported with legal confirmations. The operation

should always comply with the prosduction process. Compliance from the national

government laws up to the local government will be considered during the projects’

construction and operation.

Ethical decisions and codes will be considered based on commonly shared

values in society and the proposed location. Strong ethical codes will be

implemented as a preventive action against ethical violations that may arise when

workers show unethical behavior. Engaging employees with community volunteer

work and trainings will greatly contribute to social responsibility.


Environmental Standards

REPUBLIC ACT 9275 PHILIPPINE CLEAN WATER ACT OF 2004

The law aims to protect the country's water bodies from pollution from land-

based sources (industries and commercial establishments, agriculture and

community/household activities). It provides for comprehensive and integrated

strategy to prevent and minimize pollution through a multi-sectoral and

participatory approach involving all the stakeholders.

REPUBLIC ACT 8749 PHILIPPINE CLEAN AIR ACT OF 1999

The law aims to achieve and maintain clean air that meets the National Air

Quality guideline values for criteria pollutants, throughout the Philippines, while

minimizing the possible associated impacts to the economy.

REPUBLIC ACT 6969 TOXIC SUBSTANCES, HAZARDOUS AND NUCLEAR

WASTE CONTROL ACT OF 1990

The law aims to regulate restrict or prohibit the importation, manufacture,

processing, sale, distribution, use and disposal of chemical substances and

mixtures the present unreasonable risk to human health. It likewise prohibits the

entry, even in transit, of hazardous and nuclear wastes and their disposal into the

Philippine territorial limits for whatever purpose; and to provide advancement and

facilitate research and studies on toxic chemicals.

PRESIDENTIAL DECREE 1586 ENVIRONMENTAL IMPACT STATEMENT (EIS)

STATEMENT OF 1978

The Environment Impact Assessment System was formally established in

1978 with the enactment of Presidential Decree no. 1586 to facilitate the
attainment and maintenance of rational and orderly balance between socio-

economic development and environmental protection. EIA is a planning and

management tool that will help government, decision makers, the proponents and

the affected community address the negative consequences or risks on the

environment. The process assures implementation of environment-friendly

projects.

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