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wide range of products which improves the quality of life of humankind and
process especially when substances involved have high chemical reactivity, high
compound for the production of styrene, which in turn is used for making
ethyl benzene then gives hydrogen gas and styrene, which is vinyl benzene. Ethyl
economical manner.
activation energy and thus it leads to the formation of diethylbenzenes. To limit the
Benzene to Ethylene in the feed to the alkylation reactor. However, large excess
There are primarily two sources to produce ethylbenzene. The major being
most used method for ethylbenzene production. Different companies like Shell,
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
Solubility 0.2g/l
Form Liquid
Color Colorless
Odor Aromatic
Ethylene Properties
Formula C2H4
Benzene Properties
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
beside the national road and is also located near the waters. The figure shows the
2. Water Source
Since coolers are located all around the plant which uses water streams,
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
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
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,
will be sufficient for the feedstock needed for the production of ethylbenzene.
Product
highly flammable, colorless liquid with an odor similar to that of gasoline. This
common plastic material. In 2012, more than 99% of ethylbenzene produced was
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
gasoline and other fuels, paints and varnishes, inks, carpet glues, tobacco
reagent in producing various products, such as paints & coatings, dyes, varnishes,
Demand
demand for application as a solvent and reagents in producing paints & coatings,
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
agent, meaning it reduces engine knocking and increase the octane rating.
polystyrene resins. These resins are used to make plastic packaging, disposable
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
design options:
2.1. ISO
5. Present a simulation video of the whole production plant from the best
This chapter presents the data and information as well as the assumptions
related to the technical aspects and economical information needed for the design
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
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
while benzene will pass through a pump, also, to increase its pressure. The
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
significantly enhance the duty of the reboiler. The first distillation column will
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
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
Distillation Column
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
No. of Trays 35 – 40
Temperature Up to 140oC
Pressure Up to 17 bars
Separator
Liquid removed by the inlet diverter falls to the bottom of the vessel. The
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
volumes of total fluids and when large amounts of dissolved gas are present
with the liquid. The greater liquid surface area provides optimum conditions
Separator Specifications
Temperature Up to 40oC
Pressure Up to 19 bars
Alkylation Reactor
Transalkylation Reactor
used for the transfer of methyl and ethyl between benzene rings. It is often
Together with the process that the plant operates with, listed below
Administrative Building
Control Room
Fire Brigade
Guard House
Jetty
Parking Lot
Power Room
Process Area
Tank Farm
area of 11,000 square meters which is bound to located at Brgy. Alas Asin,
The material balance is simply taking into account of what enters and exits
mass balance, but mass balance will be used in the calculations below.
Assumptions:
m1 + m2 +m13 = m3
m1 m1 = 13,682.954 kg/hr
m3 = 63,620.591 kg/hr
m3 = 63,620.591 kg/hr
m4 = 61,711.973 kg/hr
m4 = 61,428.306 kg/hr
m14
m5 = 61,094.853 kg/hr
m6 m6 = (m5)(0.99)(3.4545 x 10-3)
m7 m7 = (m5)(0.99)(0.997)
m7 = 60,302.453
m7 = 60,302.453 kg/hr
m8 m8 = (m7)(0.96)(0.839)
m9 m9 = (m7)(0.96)(0.121)
m9 = 9,320.347 kg/hr
m9 = 9,320.347 kg/hr
m9 u
C-102 m10 = 8,777.530 kg/hr 96%
m8 m8 = 48,570.008 kg/hr
u
M-102 m12 m11 = 170.003 kg/hr 100%
m12 u
R-102 m14 = (m12)(0.97)(0.006)
Diagram Calculation
(303.15 K – 298.15 K)
Q1 = 323,408.9323 kJ
Q2 Q2 = 22,812.07075 kJ
(303.15 K – 298.15 K)
Q3 = 346,732.221 kJ
(403.15 K – 333.15 K)
Q3 R-101 Q4 Q3 = 4,854,251.093 kJ
(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
(328.15 K – 313.15 K)
Q5 = 1,026,393.53 kJ
(333.15 K – 313.15 K)
Q5 = 1,368,524.707 kJ
Q7 Q6 = 7,379.831 kJ
(333.15 K – 313.15 K)
Q7 = 1,386,956.419 kJ
(358.15 K – 328.15 K)
Q7 = 2,080,434.629 kJ
Q9 Q8 = 1,553,271.158 kJ
(358.15 K – 328.15 K)
Q9 = 483,726.009 kJ
Q9 u
C-102 Q9 = 886,831.017 kJ
(413.15 K – 358.15 K)
Q10 = 833,250.923 kJ
(413.15 K – 358.15 K)
Q11 = 18,195.421 kJ
(303.15 K – 298.15 K)
Q8 = 258,878.153 kJ
u
M-102 Q12 (303.15 K – 298.15 K)
(303.15 K – 298.15 K)
Q12 = 260,271.659 kJ
(453.15 K – 433.15 K)
Q12 u
R-102 Q13 Q12 = 1,041,086.63 kJ
Q13 = 1,632,030.04 kJ
Design Option 2
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
ethylene. Ethylene from the feed tanks will travel and pass through a
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
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
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
Distillation Column
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
No. of Trays 35 – 40
Temperature Up to 140oC
Pressure Up to 17 bars
Liquid removed by the inlet diverter falls to the bottom of the vessel. The
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
volumes of total fluids and when large amounts of dissolved gas are present
with the liquid. The greater liquid surface area provides optimum conditions
Separator Specifications
Temperature Up to 40oC
Pressure Up to 19 bars
Alkylation Reactor
used for the transfer of methyl and ethyl between benzene rings. It is often
Together with the process that the plant operates with, listed below
Administrative Building
Control Room
Fire Brigade
Guard House
Jetty
Parking Lot
Power Room
Process Area
Tank Farm
area of 11,000 square meters which is bound to located at Brgy. Alas Asin,
Assumptions:
m1 m1 = 13,682.954 kg/hr
m3 = 63,620.591 kg/hr
m3 = 63,620.591 kg/hr
m4 = 61,711.973 kg/hr
m4 m4 = 61,428.306 kg/hr
m6 m6 = (m5)(0.99)(3.4545 x 10-3)
m7 m7 = (m5)(0.99)(0.997)
m7 = 60,302.453
m7 = 60,302.453 kg/hr
m8 m8 = (m7)(0.96)(0.839)
m9 m9 = (m7)(0.96)(0.121)
m9 = 9,320.347 kg/hr
m9 = 9,320.347 kg/hr
m9 u
C-102 m10 = 8,777.530 kg/hr 96%
m8 m8 = 48,570.008 kg/hr
u
M-102 m12 m11 = 170.003 kg/hr 100%
m12 u
R-102 m13 = 46,994.144 kg/hr 97%
m15 u
C-103 m16 m16 = (m14)(0.97) 96%
Design Option 3
b. Process Description
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
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
while benzene will pass through a pump, also, to increase its pressure. The
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
significantly enhance the duty of the reboiler. Then, the separated ethane
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
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
distillation column.
Distillation Column
hence the better is the fractionation or separation of the mixture fed into the
No. of Trays 35 – 40
Temperature Up to 140oC
Pressure Up to 17 bars
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
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
volumes of total fluids and when large amounts of dissolved gas are present
with the liquid. The greater liquid surface area provides optimum conditions
Separator Specifications
Temperature Up to 40oC
Pressure Up to 19 bars
Alkylation Reactor
Transalkylation Reactor
used for the transfer of methyl and ethyl between benzene rings. It is often
Furnace
Fractionator
e. Land Area
ethylene to evolve.
m1 m1 = 13,143.388 kg/hr
m3 = 61,052.739 kg/hr
m3 = 61,052.739 kg/hr
m4 = 59,221.157 kg/hr
m4 m4 = 58,945.132 kg/hr
m5 = 58,629.157 kg/hr
m6 m6 = (m5)(0.99)(0.003)
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 = (m7)(0.96)(0.003)
m8 m8 = 46,609.796 kg/hr
u
M-102 m11 m10 = 166.662 kg/hr 100%
m11 u
R-102 m12 = 45,100.925 kg/hr 97%
Diagram Calculation
Q1 = 310,442.188 kJ
Q2 Q2 = 21,765.302 kJ
(303.15 K – 298.15 K)
Q3 = 332,737.428 kJ
(403.15 K – 333.15 K)
Q3 R-101 Q4 Q3 = 4,658,323.986 kJ
(403.15 K – 333.15 K)
Q4 = 4,642,938.709 kJ
(328.15 K – 313.15 K)
Q4 D-101 Q5 Q4 = 994,915.438 kJ
(328.15 K – 313.15 K)
Q5 = 984,969.838 kJ
(333.15 K – 313.15 K)
Q5 = 1,313,293.117 kJ
Q6 Q6 = (174.129 kg)(1.766 kJ/kg.K)
Q7 Q6 = 6,150.236 kJ
(333.15 K – 313.15 K)
Q7 = 1,330,980.951 kJ
(413.15 K – 328.15 K)
Q7 = 5,658,624.042 kJ
Q8 (413.15 K – 328.15 K)
Q7 C-101 Q9 Q8 = 4,223,313.616 kJ
(413.15 K – 328.15 K)
Q9 = 1,287,751.426 kJ
(413.15 K – 328.15 K)
Q10 = 27,567.561 kJ
(303.15 K – 298.15 K)
Q8 = 248,430.213 kJ
u
M-102 Q11 (303.15 K – 298.15 K)
Q10 Q10 = 1,654.129 kJ
(303.15 K – 298.15 K)
Q11b = 260,271.659 kJ
(453.15 K – 433.15 K)
Q12 u
R-102 Q13 Q12 = 1,041,086.63 kJ
(453.15 K – 433.15 K)
Q13 = 1,632,030.04 kJ
CHAPTER V
This chapter includes the environmental and health impacts, and safety
are negligible. Therefore, the following attentions will apply to all three design
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
environment and the ecology. More so, the EIA also checks the effects on
plant.
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
a. AIR
b. Water
in surface water are generally less than 0.1 μg/L in non-industrial areas. In
including spillage of gasoline and other fuels, leaching from landfill sites and
d. Geology
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
e. Noise
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
to know and anticipate the noise that comes from the facilities used in the
plant.
ethylbenzene for a few seconds. Irritation and chest constriction after acute-
handling each of the chemicals involved. They should also have access to
process hazard could spread, the number of workers who would potentially
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
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
The management of the plant ensures that the worksite and all
management, are held accountable for obeying site safety and health
rules.
B. Medical Services
immunizations and medical equipment for the employees and to its near
residences.
C. Personal Protective Equipment
protective equipment at all. More often than not, these are burn injuries.
ongoing effectiveness.
D. Security
(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
E. Workplace Inspection
employees.
F. Fire Drill
Waste
Wastes with potential impacts on the environment will be treated with most
international legal framework. The positive impacts that will be benefited from the
project are basically the additional material availability and reliability in the region
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.
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
can poison plant employees and release into the environment. Design must take
This section presents the socio- economic benefits of the project for each
A. Design Option I
material ethylene and benzene. The plant will have the alkylation process
B. Design Option II
Design Option II is a Ethylbenzene Production Plant with
distillation column which has three end product. It gives more efficient
eliminates the risk of leakage and lower the toxic air emissions.
Strategic decisions have the potential to impact the society and the people
around it. Decisions based on discretionary choices such volunteerism and charity
should always comply with the prosduction process. Compliance from the national
government laws up to the local government will be considered during the projects’
values in society and the proposed location. Strong ethical codes will be
implemented as a preventive action against ethical violations that may arise when
The law aims to protect the country's water bodies from pollution from land-
The law aims to achieve and maintain clean air that meets the National Air
Quality guideline values for criteria pollutants, throughout the Philippines, while
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
STATEMENT OF 1978
1978 with the enactment of Presidential Decree no. 1586 to facilitate the
attainment and maintenance of rational and orderly balance between socio-
management tool that will help government, decision makers, the proponents and
projects.