PROCESS PLANT

FOR
AROMATIC SEPARATION
Outline
Acknowledgments

Supervisor, Dr. Marcelo Castier.

Project coordinator, Dr. Samir Emam.
Dr. Samir Abu-Eishah, Dr. Nayef Mohamed
Ghasem, Dr. Sulaiman Al-Zuhair, Dr.
Mamdouh Ghannam, Dr. Mohamed Nakou
and Eng. Saad Al Omari.
Training and Graduation Projects Unit.
What are Aromatics ?
Hydrocarbons with distinctive perfumed
smell
 What is Aromatics
Extraction?

Petroleum refining industry is the largest user of

extraction.
From raw materials to daily life
products,
discover the wonders of petro
chemistry.
Summery of achievement
in GP1
Designing a process plant for aromatics
separation using naphtha reformate as feed
and Sulfolane as solvent.

Achievements in GP1 :

Literature review
Selecting the best technology
Calculating mass and energy balances
Ethics and contemporary issues
Safety and HAZOP considerations
Economic evaluation.
Summery of achievement
in GP2

Achievements in GP2:

Selecting the best types of pumps

Detailed design of major pieces like heat
exchangers and columns
Site selection for the aromatics extraction p
Materials of construction of the equipments
HAZOP study was applied to each piece of
equipment
Capital cost of the new aromatics extraction
plant
Detailed Design
Distillation

Used to separate key components in a mixture based

on the difference in their boiling points.

Distillation is energy intensive; it can consume more

than 50% of a plants operating energy cost.

The importance of column internals is to provide

better mass and heat transfers between the liquid
and vapor phases in the column.
Cont./Detailed Design
Stripper and Recovery Columns Using HYSYS

Number of trays 34 Number of trays 34

Column Diameter (m) 7.77 Column Diameter (m) 3.9

Column Height (m) 21 Column Height (m) 21
Top composition Top composition
n-heptane Toluene Sulfolane n-heptane Toluene Sulfolane
0.99 0.011 0 9.3*10-3 0.99 0
Bottom composition Bottom composition
n-heptane Toluene Sulfolane n-heptane Toluene Sulfolane
0.00162 0.17 0.83 0 3.5*10-5 0.99
Cont./Detailed Design
Stripper column hand calculation
K a Pva
ab =
K b Pvb

Using Antoine equation to calculate the vapor pressure:

B
ln P A
C T
B
log P A
C T
L av = ((top) (bottom))0.5 = 1.385
Cont./Detailed Design
X X
Log LD HW
X HD X LW
Nmin =
Log av
0.9893 0.0016
Log
0.0107 0.1716
Nmin = 28.2
Log 1.385

D X DA D X DB
* avg
Lmin
= F X FA F X FB 0.0141
F avg 1
Lmin 18.044
Lmin
Rmin 0.0562
D
Cont./Detailed Design

Assume R = 1.2
Rmin
R = 0.0674
Using Gilliland correlation
N N min R RDm
f D
N 1 RD 1
RD RDm
0.01
RD 1

N N min
0.51
N 1
N 58.63

H ( N act 1) * Trayspacin g alloewances

H (59 1) * 0.51 + 1.2 + 1.8 32.5m
Cont./Detailed Design
Recovery column hand calculation
L av = ((top) (bottom))0.5 = 316.79
XD

1 - X
ln D
XB

1- XB
N min
ln avg
N min = 2.55
N theoritical N min * 2
N theoritical 5
N th 5
N act *1.1 * 1.1 37
0.15
Cont./Detailed Design
H ( N act 1) * Trayspacin g alloewances
H (36.7 1) * 0.51 + 1.2 + 1.8 21.2 m
F

RRmin D
1
2523

437
RRmin
316.79 1 0.0183

RR 1.2 1.5 RRmin

RR 0.022 0.027
g
0.37atm * 92.14
PMwt mole g kg
v 1236 .5 1. 237
RT atm.m 3 m3 m3
8.2057 * 10 ( 5) * 336 K
mole.K

Gas velocity in the tower (u) = (1.2 -1.5)/ (1.237) 0.5=

1.08 -1.35 m/s

Vapor flow rate = 46182.4 kg/h

Volumetric flow rare, V. = (46182.4 kg/h/3600 s/h)/

(1.237 kg/m3) = 10.371m3/s
Cont./Detailed Design
.
4V 4 * 153.3
D 3.49 3.13m
* 1.08 - 1.35

Comparison between HYSYS results and hand calculation

For stripper For recovery

column HYSYS results Hand column HYSYS results Hand
calculation calculation
Nmin 34 59 Nmin 34 37

Height (m) 21 32.5 Height (m) 21 21.2

Diameter Diameter
7.7 7.7 3.9 3.49 3.13
(m) (m)
Cont./Detailed Design
Vessels
Cont./Detailed Design
Vessels

Vessel Diameter(m) Height(m)

Raffinate wash column (V-101) 0.9368 2.811

Stripper Receiver (V-102) 1.695 5.085

Recovery Column Receiver (V-

103)
1.447 4.341
Cont./Detailed Design
Extraction Column (T-101)
Cont./Detailed Design
LLE
Cont./Detailed Design
LLE
Mass balance of sulfolane (input streams)
Cont./Detailed Design
Pumps
According to the value of the head, the pump type will be selec

The expected maximum head for each type of pump

Type of pump Maximum head (m)

Centrifugal pump 152

Axial pump 12

Rotary pump 15200

Reciprocating pump 300000

To calculate the head of the pump, the following equation is

used: P
P g h H
g
Cont./Detailed Design
Pumps

For example, pump P101 A/B

P1=1 bar to P2= 8.83 bar.
The density of the mixture is 848.5 kg/m3
(8.83 1) 10 5 Pa
H 94.068m
kg m 2
848.5 3 9.81
m s

value of the head does not exceed 125m

Cont./Detailed Design
Pumps
To find the power of the pump this equation was used:

kW 1.67 Flow (m
3

min

) Pr essure drop (bar) / Effeciency

Effeciency 80 0.2855F 3.78 10 4 FG 2.38 107 FG 2 5.39 10 4 F 2

- 6.39 10 4 F 2G 4 1010 F 2G 2

Where:
F is the head in feet
G is the flow rate in gallon per minutes (gpm)
Cont./Detailed Design

Pumps
m (kg )
v hr
(kg 3 ) 60 min 1hr
m
The molecular weight of benzene is 78.11 kg/mol and for octan
114.23 kg/mol
Mwavg (0.899 78.11) (0.101 114.23) 81.77 kg / kmol

m n Mwavg 383.89 kmol 81.77 kg 31389.27 kg
hr kmol hr

31389.27 kg
v hr 0.617 m
3

min
848.5 kg 3 60 min
m 1hr
3 1m 3 6.32 10 4
gallon
0.167 m
min 264.17 gallon min
3.28084 feet
94.068m 308.62 feet
1m
Effeciency 51.37%

Power 1.67 0.617 (m
3

min

) (8.83 - 1)(bar) / 0.5137 15.69 kW
Cont./Detailed Design
Pumps Pin (bar) Pout (bar) Head (m) Volumetric Flow rate Efficiency % Power (kW)
(m3/min)
P101 A/B 1 8.83 94.07 0.6166 51.37 15.69

P102 A/B 1 6.1 41.43 0.00091 51.17 0.01514

P103 A/B 0.59 6.1 48.05 1.5736 61.79 23.43

P104 A/B 0.48 8.83 72.07 0.2147 45.56 6.57

P105 A/B 0.37 5.08 48.12 0.0470 48.90 0.7554

P106 A/B 1.41 8.83 110.65 0.9060 58.14 19.301

P107 A/B 0.48 2.05 16.98 4.8593 70.45 18.08

P108 A/B 0.65 6.1 47.44 0.01653 48.81 0.3081

Cont./Detailed Design
Heat exchangers
For our plant, shell and tube heat exchanger was chosen to
transfer heat between fluids.
The reasons are:
It provides large ratio of heat transfer area to volume and
weight.
Its shape allows easy construction in a wide range of sizes
that can withstand shop fabrication stresses, shipping and
field erection stresses and normal operation conditions.
It can be easily cleaned and if failure occurs, elements such
as tubes and gaskets can be easily replaced.
Cont./Detailed Design
Heat exchangers
. .
q m oil C P ,h (Th ,in Th ,out ) m water C P , water (Twater ,in Twater ,out )
99 37.8
Tbulk 68.4 C
2

At Tbulk 68.4o C C P ,h 2393 J

kg.C
.
q m h C p ,h (Th1 Th 2 ) (1.25 kg )(2393)(99 37.8) 183267.905W
s
.
q m c C P ,c (Tc1 Tc 2 )

183267.905W (m c kg )( 4224 J o )( 45 30) C
o
s kg. C

m c 2.89 kg
sec
 Heat exchangers
T2 T1
Tlm
T
ln 2
T1 T1= 54oC

T1 99 45 54 o C Th1=99oC
T2 37.8 30 7.8 o C
Tlm 23.88 o C Tc1=45oC
T2= 7.8oC

q UATlm Th2=37.8 oC
q 183267.905W
UA 7675.28W o
Tlm o
23.88 C C Tc2=30oC

assu min g U 450W

m 2 .o C

W
UA 7675.28 o C
A 17.0562m 2
U 450W 2 o
m . C
 Heat exchangers
assu min g L 5m

A 17.0562
ndp 1.0858 m
L *5
From table A-11 (Holman, 2002) at nominal pipe
size =1/8 in
IDtube 0.269in 6.833 * 10 3 m

ODtube 0.405in 0.010287 m

ndp 1.0858
n 3
158.919 159tubes
dptube , in 6.833 * 10
Dshell n * dp out

n * dp out 159 * 0.010287 0.1297 m 5.1069in

:

Heat exchangers

Dshell 5.761in 0.14633m

Dshell 0.14633m n * dp out 0.1297 m

Properties of the mixture at Tb 68.4o C

669.1 kg
m3
Pr 6.918
k 0.1155 W
m.o C
0.0003339 kg m.s
w 0.0002528 kg m.s
2
4.99 10 7 m s
 Heat exchangers

Atubes ,cross
* n * IDtube2

4

* 159 * (6.832 * 10 3 m) 2 0.0058299m 2
4
.
m * u * Atubes ,cross
.
m
u
* Atubes ,cross
1.25 kg
s 0.320806 m
s
669.1 kg 3 * 0.0058299m 2
m
u * dpin
Re

0.320806 m * 6.833 * 10 3 m
s 4392.66 turbulentflow
7 m 2
4.99 10
s
0.14

Nu d 0.027 Re 0.8 Pr 1 / 3
w
 Heat exchangers

0.14
0.0003339 kg
m. sec
Nu d 0.027 (4392.66) 0.8 (6.918)1 / 3
0.0002528 kg
m. sec
Nu 43.898

W
Nu * k 43.898 * 0.1155 m. o C
hin 742.068 W 2 o
IDtube 3
6.833 *10 m m . C
 Heat exchangers

The Properties of water at Tb 37.5 C

30 45
Tb 37.50C
2
Shell calculation:

993.096 kg
m3
6.862 10 4 kg m.s
w 8.03 10 4 kg m.s
k 0.6304 W o
m. C
2
v 6.9097 10 7 m
sec
Pr 4.559
 Heat exchangers

Ashell 2
* Dshell * n * ODtube
2

4 4

* 0.146332 m 2 *159 * 0.010287 2 m 2 0.0036023m 2
4 4
.
m * u * Ashell
.
m
u
* Ashell
2.89 kg
s 0.80855 m
s
993.096 kg 3 * 0.0036023m 2
m

4 Ashell 4 Ashell
HD
P d shell + n dp out
 Heat exchangers

4 * 0.0036023m 2
HD 0.0025739m
* 0.14633 m *159 * 0.010287 m

m
u * HD 0.80855 s * 0.0025739 m
Re HD 3011.84 turbulentflow
9.9097 *10 m
7 2

s
0.14

Nu d 0.027 Re 0.8
Pr 1/ 3


w
0.14
6.862 10 4 kg
1/ 3 m . sec
Nu d 0.027 * (3011.84 ) ( 4.559)
0.8

8.03 10 4 kg
m. sec
Nu d 26.576
 Heat exchangers
W
Nu * k 26.576 * 0.6304 m.o C
hout 6509.168W 2 o
HD 0.0025739 m m . C
1
U
dp out 1

dpin * hin hout
1
458.185W
0.010287 m 1 m 2 .o C

6.833 *10 3 m * 742.068W 6509.168 W
m 2 .o C m 2 .o C

UA 7675.28W o
A C 16.751 m 2
U 458.185 W 2 o
m . C
Atube ndpin L
A 16.751 m 2
L 4.908m
ndpin 159 * * 6.833 10 3 m
 Heat exchangers
The properties of this shell-and-tube heat
exchanger
. (E-101) are:
m h 1.25 kg
s
Th1 99 o C
Th 2 37.8 o C
Twater ,in 30 o C
Twater ,out 45 o C
.
m water 2.89 kg
s
IDtube 0.269in 6.833 *10 3 m
ODtube 0.405in 0.010287m
Dshell 5.761 in 0.14633 m
n 159tubes
A 16.751m 2
U 458.185W
m 2 .o C
Length 4.908m
 Heat exchangers
The properties of heat exchangers E-102
are as follows:
.
m h 12.78 kg
s
Th1 120 Co

Th 2 46o C
Twater ,in 30 o C
Twater ,out 45o C

IDtube 0.269in 6.833 *10 3 m

ODtube 0.405in 0.010287m
Dshell 2.900in 0.07366m
n 27tubes
A 2.8657 m 2
U 21769.298 W
m 2 .o C
Length 4.944m
 Heat exchangers
The properties of heat exchangers E-103 are as
follows:
.
m h 8.27 kg
s
Th1 63 C o

Th 2 37.8 o C
Twater ,in 30 o C
Twater ,out 45 o C
.
m water 6.4185 kg
s
IDtube 0.269in 6.833 *10 3 m
ODtube 0.405in 0.010287m
D shell 9.75in 0.24765m
n 281tubes
A 30.085m 2
U 1108.23 W
m 2 .o C
Length 4.987m
Cont./Detailed Design
Materials of construction
(MOC)
The selection of materials of construction for equipment and
facilities to produce chemicals is a core subject of chemical
engineering.
The desired products can not be manufactured without
considering the selection of optimum materials of construction
used in the equipments of the process plant for:

Safe.
Economical manufacture.
Required product quality.
 Cont./ Materials of construction
(MOC)
The selection of materials of construction is guided by several important
points such as:
The corrosion of the materials by the chemicals used in the process.
The temperature.

All the equipments are operated below 400oC, carbon steel is

selected because it is cheap and strong.
Extraction Stripping Raffinate Solvent Water Solvent Stripper Recovery
column column water recovery Stripper regenerato receiver column
wash column r receiver
column
Temperature Top 99 118 37.8 63 110 177 46 63
(oC)
Bottom 85 168 37.8 169 121 - 46 63
Pressure Top 6.10 1.88 5.08 0.37 1.41 0.68 1.41 0.37
(atm)
Bottom 8.83 2.22 5.08 0.59 1.48 - 1.41 0.37
Cont./ Materials of construction
(MOC)
Solvent regenerator reboiler which is constructed from stainless
steel.

The reason behind this is that sulfolane is a very stable

extraction solvent, but over time, and at high temperature in
the presence of oxygen, it can form acidic compounds.
Cont./ Materials of construction
(MOC)
The following four items are the main causes for
corrosion/erosion problems in the aromatics extraction
unit using sulfolane:

Oxygen in the plant.

Chlorine in circulating solvent.
Accumulation of degradation and corrosion products in
the plant.
High temperature in reboilers.
Cont./Detailed Design
Optimization of process variables
Total module cost for different areas
Thin T cout Thout Tcin
T ln
Thin T cout
ln
Thout Tcin
Q UA T ln
Q
A
U T ln
Total module cost for different areas
Exchangers Type of Tube MOC Area Purchased Bare
Exchanger Pressure (square Equipment Module
(barg) meters) Cost Cost

E-101 Multiple Pipe 6.18 Carbon Steel / Carbon Steel 15.8 $ 5,630 $ 18,500

Multiple Pipe 6.18 Carbon Steel / Carbon Steel 16.8 $ 5,940 $ 19,500

Multiple Pipe 6.18 Carbon Steel / Carbon Steel 17.8 $ 6,300 $ 20,700

Multiple Pipe 6.18 Carbon Steel / Carbon Steel 20.6 $ 7,210 $ 23,700

E-102 Multiple Pipe 1.15 Carbon Steel / Carbon Steel 26.1 $ 9,000 $ 29,600

Multiple Pipe 1.15 Carbon Steel / Carbon Steel 30.1 $ 10,300 $ 33,900

Multiple Pipe 1.15 Carbon Steel / Carbon Steel 36.1 $ 12,300 $ 40,400

Multiple Pipe 1.15 Carbon Steel / Carbon Steel 46.5 $ 15,700 $ 51,700

Multiple Pipe 1.15 Carbon Steel / Carbon Steel 73.1 $ 24,800 $ 81,500

E-103 Multiple Pipe 0.37 Carbon Steel / Carbon Steel 2.87 $ 3,730 $ 12,300

Multiple Pipe 0.37 Carbon Steel / Carbon Steel 2.99 $ 3,730 $ 12,300

Multiple Pipe 0.37 Carbon Steel / Carbon Steel 3.13 $ 3,730 $ 12,300

Multiple Pipe 0.37 Carbon Steel / Carbon Steel 3.29 $ 3,730 $ 12,300
Total module cost for different types
of pumps
Pumps Pump Type Power # Spares MOC Discharge Purchased Bare Module Cost
(with drives) (kilowatts) Pressure (barg) Equipment Cost

P-101 Centrifugal 15.7 1 Carbon Steel 8.83 $ 6,280 $ 25,000

P-102 Centrifugal 0.015 1 Carbon Steel 6.1 $ 3,270 $ 13,000
P-103 Centrifugal 23.4 1 Carbon Steel 6.1 $ 7,510 $ 9,900
P-104 Centrifugal 6.47 1 Carbon Steel 8.83 $ 4,560 $ 18,100
P-105 Centrifugal 0.755 1 Carbon Steel 6.1 $ 3,270 $ 13,000
P-106 Centrifugal 19.3 1 Carbon Steel 8.83 $ 13,700 $ 54,700
P-107 Centrifugal 18.1 1 Carbon Steel 2.05 $ 6,670 $ 26,600
P-108 Centrifugal 0.308 1 Carbon Steel 6.1 $ 6,530 $ 26,000
P-101 Positive Displacement 15.7 1 Carbon Steel 8.83 $ 14,000 $ 53,000
P-102 Positive Displacement 0.015 1 Carbon Steel 6.1 $ 6,000 $ 22,800
P-103 Positive Displacement 23.4 1 Carbon Steel 6.1 $ 17,100 $ 64,800
P-104 Positive Displacement 6.47 1 Carbon Steel 8.83 $ 9,600 $ 36,400
P-105 Positive Displacement 0.755 1 Carbon Steel 5.08 $ 6,000 $ 22,800
P-106 Positive Displacement 19.3 1 Carbon Steel 8.83 $ 15,500 $ 58,700
P-107 Positive Displacement 18.1 1 Carbon Steel 2.05 $ 15,000 $ 56,800
P-108 Positive Displacement 0.308 1 Carbon Steel 6.1 $ 6,000 $ 22,800
P-101 Reciprocating 15.7 1 Carbon Steel 8.83 $ 52,800 $204,000
P-102 Reciprocating 0.015 1 Carbon Steel 6.1 $ 9,470 $ 36,600
P-103 Reciprocating 23.4 1 Carbon Steel 6.1 $ 68,000 $263,000
P-104 Reciprocating 6.47 1 Carbon Steel 8.83 $ 32,200 $124,000
P-105 Reciprocating 0.755 1 Carbon Steel 5.08 $ 13,600 $ 52,500
P-106 Reciprocating 19.3 1 Carbon Steel 8.83 $ 60,100 $232,000
HAZOP Study
Results of HAZOP of Pumps P-101A/B, P-102A/B, P-103A/B, P-104A/B, P-105A/B,
P-106A/B, P-107A/B and P-108A/B
Guide Deviation Possible Causes Consequences Actions Required
Word
None No Flow - No feed material - Outlet stream reduced - Install low level alarm.
being available. - The temperature increases - Ensure good communication
causing damage. with storage operator.

- Line Blockage, - Outlet stream reduced - Check design of pump

Isolation valve - The temperature increases strainers
closed in error, causing damage. - Pipes maintenance
LCV fails shut - Installation for flow control.

- Line fracture - Outlet stream reduced - Covered by a)

- The temperature increases - Institute regular patrolling and
causing damage. inspection of transfer line
Cont./HAZOP Study
More Flow - LCV fails or LCV - Low Outlet stream - Install high flow alarm
of bypass open in - It may overload (HFA) and check sizing of
error motor. relief opposite liquid over
- More Material filing.
flow - Repair FCV

Pressure - Isolation valve Failure of MOC - Check lines and reduce

closed in error or stroking speed of LCV id
LCV closed. necessary.
- Plug in pipe

Temperature - TCV Failure - High Temperature - Install a high Temperature

in transfer line. alarm
- Loss of cooling - Affects tensile - Repair TCV
water due to strength of MOC
pump failure - Plant shut down - Do a circulation for the
feed to avoid plant
- Higher shutdown and do the
consumption for maintenance mean while.
cooling water in
other unit which
decrease the
cooling water.

Less Flow - FCV Failure - Material Loss - Repair FCV

of - Low outlet stream

- Low material flow

- Leaking
Cont./HAZOP Study
Pressure - Inlet valve or suction line may be - Optimum condition not reached - Low pressure alarm
clogged - MOC failure if vacuum reached (LPA)
- Causes cavitations which will damage
the component of the pump. - Maintain inlet valves
- Great deal of noise.
- Vibration and less of efficiency.

Temperature - TCV Failure - Plant shut down - Low Temperature

Alarm (LTA)

- Decrease the
processing flow rate
to optimum rate

- Repair TCV
Maintenance - Equipment Failure - Line cannot be completely drained or - Install alarms.
purged
Cont./HAZOP Study
Results of HAZOP for Extractor column T-101
Guide Word Deviation Possible Causes Consequences Actions
Required
None No Flow - No naphtha - The column may be washed by solvent, leaving from - Install low
feed available the bottom. (Quality and amount of product will level alarm.
suffer)

- No solvent flow - No separation of the naphtha feed - Install low

level alarm
- Line fracture - Accidental discharge to the environment (aromatics - Plant shut
are flammable material). down.

More of Flow - LCV fails open - Erosion. - Further

in error - Overload the equipment. evaluation of
- Overfills additional cut-
- Material carry-over or inefficient separation. off valve and
shutdown
system.
Cont./HAZOP Study
Pressure - Isolation valve close in
error
- Failure of a vessel or the
associated piping leading to
-
-
Pressure relief device.
High pressure alarm (HPA)
sequence events that result in a - Back up pump
disaster.
- Maintain pipe
- Other streams may be diverted
leading to spillage.
More flow of - Control valves fail open or Decrease selectivity of the - Install high level alarm and
solvent too far open or misdirected separation. check sizing.
when on manual (FCV
Failure).
- Action reversed or
controller.
- More material flow
Temperature - Higher pressure in transfer - Uncontrolled mixing of water with - Equip the system with
line hydrocarbons which generate pressure relief device.
- High miscibility. high pressure conditions causing
damage. - High Temperature Alarm
- TCV Failure
(HTA).
- The components present in the - Repair TCV.
mixture will flash to steam and
then can rupture pipes and
vessels.
Cont./HAZOP Study
Less of Flow of solvent - Incorrect rate of process flows. - Aromatic compounds - Isolate that
may well be lost to the part of the
- FCV Failure. raffinate providing a plant
- Low material flow. pure product but - Repair FCV
achieving a less than
complete recovery.

Others Maintenance - Equipment Failure - Line cannot be - Install

completely drained or alarms.
purged
Cont./HAZOP Study
Results of HAZOP for Water wash column V-101

Guide Word Deviation Possible Causes Consequences Actions

Required
None Flow - No non-aromatic - Water coming from stream 13 - Install low level
compounds only pass through the alarm

equipment
- low separation of non-
aromatic

- Line fracture Accidental discharge to the - Plant shut

environment. down.
More of More flow of - LCV fails open in error - Overfills - Install high
water coming - Water washes more material of level alarm
from recovery and check
the non-aromatics
column receiver sizing.
Cont./HAZOP
Results of HAZOP for Stripper Study
column T-102

Guide Word Deviation Possible Causes Consequences Actions

Required
None No Flow - No flow in stream - Quality and amount of product will suffer. - Install low level
9 coming to the alarm
column
- Line fracture - Accidental discharge to the environment - Plant shut
(aromatics are flammable material). down.

More of Flow - LCV fails open in - Overfills - Install high

error - Incomplete separation of non-aromatics from level alarm and
solvent + aromatics check sizing.

Pressure - Isolation valve - Full pump delivery - Isolation valve

close in error close in error
Temperature - Higher pressure in - Degradation of the solvent quality will become - High
transfer line significant ms. Temperature
Alarm (HTA).
Cont./HAZOP Study
Less of Flow - Leaking flange of valve - Material discharge - Isolate that part of
to the environment the plant

Others Maintenance - Equipment Failure - Line cannot be - Install alarms.

completely drained
or purged
Cont./HAZOP
Results of HAZOP for RecoveryStudy
column T-103
Guide Deviation Possible Causes Consequences Actions Required
Word
None No Flow - No flow in stream 11 - No aromatic separation - Install low level alarm
- Line fracture - Accidental discharge to the - Plant shut down.
environment
More of More flow of - LCV fails open in error - Erosion. - Install high level alarm
solvent rich - Overload the equipment. and check sizing.
aromatics - Leaks from other process.
- .
Pressure - Isolation valve close in - Failure of a vessel or the associated - High pressure alarm
error piping (HPA)
- Back up pump
Temperature - Higher pressure in - Degradation of the solvent which - High Temperature Alarm
transfer line leads to fouling and corrosion (HTA).
problems. - Repair TCV.
Less of Flow - Leaking flange of valve - Material discharge to the - Isolate that part of the
- Incorrect rate of process environment plant
flows. - Repair FCV
- FCV Failure.
- Low material flow.
Cont./HAZOP StudyV-104
Results of HAZOP of Solvent regenerator
Deviation Causes Consequences Action

More of Temperature - TCV Failure - Solvent degradation
causing corrosion to the
equipment.
- Equip the system with pressure relief
device.
- High Temperature Alarm (HTA).
- Repair TCV.

Pressure - Blockage in some of - Failure of a vessel or the - Pressure relief device.

the outlet streams. associated piping leading to - High pressure alarm (HPA)
- High flow in the inlet sequence events that result - Back up pump
streams. in a disaster. - Maintain pipe

Flow - Control valves fail - Erosion. - Further evaluation of additional cut-off

open or too far open - Overload the equipment. valve and shutdown system.
or misdirected when - Leaks from other process - Restriction orifice in line.
on manual (FCV streams or the environment.
Failure). - Material carry-over or - High flow alarm (HFA)
- Action reversed or inefficient separation. - Repair FCV
controller.
- More material flow
Cont./HAZOP Study
Less of Temperature - TCV Failure - Low separation efficiency. - Low Temperature
alarm (LTA)
- Repair TCV
Flow - Incorrect rate of process flows. - Less separation - Repair FCV
- FCV Failure
- Low material flow
Pressure - Inlet valve or suction line may be - Optimum condition not - Low pressure alarm
clogged reached (LPA)
- Maintain inlet
valves
Level - Low flow in the feed stream. - Can result in gas entering - Low flow alarm
the heat exchanger surface. (LFA)
None Flow - Plug in pipe - No separation - Low flow alarm
- pipe ruptures (LFA)
- No materials flow - Pipes maintenance
- Installation for flow
control and pumps
to increase the flow
upon loss.
 Site Selection
The initial drive of this project is the interest of ENOC, a
Dubai-based company, to separate aromatics. The Dubai
area was there for our first choice.
Jebel Ali Free Zone was chosen as the best location to
construct the plant.
Why JAFZA
Jafza is built over an area of
48 square kilometers, a few
kilometers from the city of
Dubai. It ranks among the
worlds largest and the
fastest growing free zones.
Free Zone Analysis
Demographic Analysis: All labor available with different educational levels.
Trade Area Analysis: Feasibility of accessing the trade area.
Competitive Analysis: The nature, location, size and quality.
Traffic analysis: Logistics for transporting raw materials and products.
Site economics: Establishment and operational costs are fair as there is no
taxes.
 Alternative Site, Ruwais

Refinery
The Ruwais Refinery is to the west of Abu Dhabi about 240 kilometers. It was built in
the 1970s. It was officially opened in 1982. It started with 120,000 barrels per day
(bpd) and, in June 1981, a 27,000 bpd were added later.

HSE (Health, Safety & Environment) at Ruwais

Safety and operations comply with the ADNOC Environmental Protection, Occupational
Health and Safety policy.
 Cost Analysis
Economics refers to evaluating the operating and capital costs that
is related with the operating and constructing of a new chemical plant.
Capital cost associated with the construction of a new plant. It is
concerned with design, constructions, equipment and their installation,
piping, control systems, buildings and structure, auxiliary
facilities(utilities and land).
Capital Cost
The CAPCOST
program will be used to
calculate the fixed
capital cost.
It takes into account
direct and indirect cost,
contingency, fees, and
auxiliaries.

Bare Module C
ost
Manufacturing Cost
 CAPCOST
e CAPCOST program is used to determine the capital cost of different
f equipment in the process plant, which are heat exchangers, pumps,
vessels, extraction and distillation columns.

Discharge Pressure Purchased Bare Module

Pumps Power (KW)
(barg) Equipment Cost Cost
P-101 15.7 8.83 $ 6,280 $ 25,000
P-102 0.015 6.1 $ 3,270 $ 13,000
P-103 23.4 6.1 $ 7,510 $ 9,900
P-104 6.47 8.83 $ 4,560 $ 18,100
P-105 0.755 6.1 $ 3,270 $ 13,000
P-106 19.3 8.83 $ 13,700 $ 54,700
P-107 18.1 2.05 $ 6,670 $ 26,600
P-108 0.308 6.1 $ 6,530 $ 26,000
All pumps are centrifugal

Area (square Purchased Equipment

Heat Exchangers Bare Module Cost
meters) Cost
E-101 30.1 $ 13,700 $ 45,200
E-102 2.86 $ 4,970 $ 16,400
E-103 16.8 $ 7,920 $ 26,000
All heat exchangers are multiple pipes and are
centrifugal.
Cont./CAPCOST
Distillation Height Diameter Pressure Purchased Bare Module
column (meters) (meters) (barg) Equipment Cost Cost
T-101 45 9 1 $ 2,350,000 $ 10,400,000
T-102 39 7.7 2.22 $ 1,490,000 $ 7,870,000
T-103 21 3 0.59 $ 127,000 $ 515,000
All purchased towers are empty vertical vessel

Diameter Purchased
Length/Height Pressure Bare Module
Vessels Orientation Equipment
(meters) (barg) Cost
(meters) Cost
V-101 Vertical 2.81 0.937 5.08 $ 5,750 $ 23,800
V-102 Horizontal 5.09 1.7 1.41 $ 15,200 $ 45,900
V-103 Horizontal 4.34 1.44 0.37 $ 11,700 $ 35,200

Total purchased cost = $ 4,078,030

Utilities cost
The costs of utilities are influenced by the cost of
fuel affecting the cost of electricity, steam, and
thermal fluids.

Pumps
pump - 101 A/BPower
15.69 KW
actual power 15.34KW
0.96
$
electric substitution 0.06
KW.hr
$ hr day
cost 15.34 KW 0.06 24 365 0.95 $ 7662.56 /year
KW.hr day year

P-101 P-102 P-103 P-104 P-105 P-106 P-107 P-108

A/B A/B A/B A/B A/B A/B A/B A/B

Power (kW) 15.69 0.015 23.43 6.47 0.75 19.30 18.08 0.308

Power/ (kW) 15.34 0.0156 24.40 6.73 0.78 20.104 18.83 0.3208
12183.4 10038.3
Cost ($/yr) 7662.56 7.79 3360.42 389.47 9402.20 160.18
1 3
Cont./Utilities cost
Cooling water

Heat Duties of equipments

Heat exchangers (GJ/hr) 10.7006
Stripper column(GJ/hr) 1.656*10-8
Recovery column(GJ/hr) 1.51*10-9

Total amount of duty 10.7006 GJ/hr

Cost of cooling water 0.354$/GJ
$ hr day
Total Cost 10.7006GJ/hr 0.354 24 365 0.95 31523.839 $/year
GJ day year
Materials cost
Sulfolane cost
Sulfolane cost is equal to $4000/tones, where the total
amount required in the process is 6.228 tones/year.

Total cost of material = $4000/tones * 6.228 tones/year =

24,914.57 $/year
Mass of Sulfolane (Kg/hr) 0.068
Density of Sulfolane(Kg/m3) 1261
(hr) 0.25
mass/density 0.000053
V(m3) 0.000013
annual purchase ($/yr) 0.00243
Cost of labor
total number of week/year 52weeks/year
total number of work week/labor 49weeks
number of shift /week.labor 5shift/week.labor
number of shift /year.labor 49weeks/year 5shifts/week.labor 245shifts/year
24hr/day
number of sheft /year 3shift/day
8hr/shift
total number of shift/year 365day/year 3shifts/day 1095shifts/year
1095shifts/year
number of operator needed in the plant at any time 4.47
245shifts/yrear.labor
Nol 6.29 31.7P 2 0.23 N np
Nol number of labor
P 2 number of solid handling
N np number of equipment
Nol 6.29 31.7(0) 2 0.23 11 2.97
Nol 2.97 4.47 13.28 14labor
shifts hours $ $
working hour 245 8 25 50,000
year shifts hour year
$ $
cost of labor 14 50,000 700,000
year year
Profit Calculations
Total capital cost $ 4877512.59
COM $ 3,330,399
depreciation= 0.1 TCC 0.1
Tax rate 0.2
BTX selling price $/Ib 3.95
BTX density 0.8765

Total amount of BTX produced is 835,438.9425

tones/year
Income from sale Production rate (tones/yr) Selling price ($/tones)
835438.94 (3.95 * 2204.62) 7275210336 $
year
Net income Income from sale - COM 7,271,879,936 $
year
Profit before tax Net income 7,271,879,936 $
year
tax Net income tax rate 7,271,879,936 0.2 1,454,375,987.27 $
year
Profit after tax Profit before tax tax 5,817,503,949.10 $
year
Depreciation 0.1 Total Capital Cost 487,751.25$
Cash Profit after tax depreciation 5,817,991,700.36 $
year
Safety & Environmental impact
Hydrocarbon toxicity stands for toxic
intake of either petroleum or
nonpetroleum-distillate hydrocarbons.

It has a considerable absorption through

the human digestive system causing:
Local toxicity (breathing problems,
choking, vomiting, cough, long term
fever).
Systemic toxicity (depression, euphoria,
headache, dizziness and heart failure in
severe cases).
Cont./Safety & Environmental impact
There is a large body of toxicity data
related to aromatic extract (hazardous
products ).

Long-term exposure to high levels of

benzene vapor can cause serious health
risks which has been classified as a
human carcinogen by the International
Agency for Research on Cancer (IARC).
 Conclusion
The objective was to design of a process plant that handles
approximately 37.89 m3/hr of an aromatic-rich blend of
pyrolysis naphtha and coke oven light oil to separate
aromatics such as benzene, toluene and xylenes by using an
aromatic-selective solvent (sulfolane).

Following missions were done: Material and energy balance,

Design of every piece of equipment, Hazop study, safety and
ethical considerations, cost analysis and the site selection.