Group Members: Group Leader: Mohammad Al-Kashan Barjas Al-Otaibi Nasser Sohail Ahmad Boland Mutlaq Al-Shamery

Agenda Introduction Description of flowsheet. Comparison between results & SRI Results. Comparison of overall Hysys & hand calculation results. Comparison between conversion & equilibrium reactor results. Overall Conclusion

Introduction Ethylbenzene is an organic compound with the formula C 6 H 5 CH 2 CH 3. This aromatic hydrocarbon is important in the petrochemical industry as an intermediate in the production of styrene. Styrene is used for making polystyrene, a commonly used plastic material.

The benzene (stream1) fed to the tank (V-100) then continues to the first distillation column (C- 202). This column is called benzene fractionator that is used to separate benzene from other components.

Benzene Fractionator (C-202)

Specifications of C-202 Column specificationsSpace value Reflux ratio5 Component recovery0.97 Component recovery 20.99

The outlet Liquid overhead of column (C-202) (Stream 4) is separated to two streams; first stream will enter the shell of first heat exchanger and exist as shell outlet. the stream will fed to the compressor to increase the stream pressure. Stream 8 will enter the heater(E-104) the temperature of feed will increase to 405 C and will combined with a large amount of ethylene that separate from stream 2 then fed to the first reactor (bed 1).

The second stream will combined with a small amount of separated ethylene from stream 2 then it will enter to the shell of the second heat exchanger. The stream will exist from the second heat exchanger as (stream 7) and then will enter the Tee unit and will separate to five streams. These streams are used to adjust and control the reactions inside the reactors and to decrease the temperature of the reactors since we have exothermic reaction that produced heat energy.

Reactor (Bed1)

Reactions involved C 6 H 6 + C 2 H 4  C 6 H 5 CH 2 CH 3 C 6 H 6 +n C 2 H 4  C 6 H 5 (CH 2 CH 3 ) n C 6 H 6 +n C 2 H 4  C 6 H 5 (CH 2 CH 3 ) n, n = 10 (Heavies). C 6 H 5 CH 2 CH 3 + H 2 O  C 2 H 6 + CH H 2 C 6 H 5 CH 2 CH H 2 O  C 6 H 6 + CH 4 + CO H 2

the change of conversion for each reaction ReactionsFirst Estimation Second Estimaation Third Estimation Rxn Rxn Rxn 135E-51E-48E-4 Rxn 143E-38E-31.25E-2

Reactor Bed1 worksheet Reactor Bed1 worksheet

The Influents of the first reactor will enter the second reactor (bed2) and the same reactions will be consumed with the same value of conversion. The set (bed2) that contains the same type of reactions will take place in the second reactor. The amount of ethylbenzene will increase at the outlet stream of the second reactor (Stream B22) and the amount of ethylene will decrease rapidly in first two reactors.

The influents of six bed reactors will enter the tube of the first heat exchanger (E-105). The temperature of the influents will decrease then the feed will enter in second heat exchanger (E-107) and exist as stream 10. Stream 10 will enter to the first distillation (benzene fractionator) separation process will take in place and most of ethylbenzene will exist from the bottom of the first distillation to enter to second distillation.

Ethylbenzene Column (C-203) Stream 15 will enter the second distilation that is called (ethylbenzene column) Separation process will take place in this column and ethylbenzene will go as overhead product. Ethylbenzene will exist from the column as an overhead and will enter to the cooler to decrease its temperature to 66 C and exist the plant as our main product.

Design of Ethylbenzene Column

Ethylbenzene Column Worksheet

Polyehtylbenzene column Polyethylbenznene with other components (stream 16) and enter the third column (poylehtylbenzene column). In this column is used to separate polyethylbenzene as an over head product and the other components will exist from the bottom as residues so that we can use it as fuel.

Design of Polyethylbenzene Column

Polyethylbenzene column Worksheet

Transalkylation Reactor (R-102): Transalkylation process is take a place in this reaction and it used to crack the bond of polyethylbenzene to form ethylbenzene. The reactor is work at 400 C and 100 Psig with same reactions and conversion used in the six bed reactors.

Design of R-102 Reactor Heavies and water will exist from the top of the column and enter to couple of coolers connected in series then to the three-phase seperator. Vent gas will burn as fuels and waste water will send for treatment. Finally The components that exist from the bottom of the column will recycle back to the C- 202.

Refluxed Absorber (C-201):

Design of Refluxed Absorber

Three-Phase Seperator (V201):

Overall Mass Balance Mass in = Mass out Total Benzene In:- Benzene in = Ib/hr Total Benzene Out:- Wastes water Stream = 0 Vent gas Stream = Ib/hr Residue Stream = 0 Ethylebenzene Stream = Ib/hr

Mass converted of benzene = [mass in – (streams out )]/ mass in = [( )/(108600) ]* 100 = % Total Ethylene In:- Ethylene In = = Ib/hr Total Ethylene Out:- Vent gas = Ib/hr Mass converted = [mass In – (streams out )/ mass In]*100 = %

Mass Balance Cont’ Amount of Ethylbenzene:- Mass benzene in + Mass ethylene in = (108600) ( ) = Ib/hr Amount of Ethylbenzene (Theoretical) – Amount of Ethylbenzene (Simultaneous) = – E5 = Ib/hr

Cont’ Total mass out:- Ethylbenzene = kg/hr Residue = kg/hr Va = kg/hr Liquid = kg/hr Heavies = kg/hr Total out = kg/hr

ReactorsMass in (kg/hr)Mass out (kg/hr) Bed Bed Bed Bed CRV CRV CRv

ReactorsTemperature ( c )Pressure ( Kpa) Bed Bed Bed Bed Bed Bed CRV

Heat ExchangersTypeDelta T ( c) E-111cooler E-104heater238 E-106cooler E-103heater168.4 E-102cooler E-101cooler E-100cooler E-108heater60.46 E-105Shell & TubeTube Side = -44 Shell Side = E-107Shell & TubeTube Side = -40 Shell Side = E-112cooler-190 E-113cooler E-110cooler E-109cooler-154.6

SRI Results

SRI Results Cont’

SRI Results Cont,

Hysys Results

Hysys Results Cont’

Overall conclusion - More unit has been added in this plant because:- The difference between actual flow sheet and hysis to get the control temperature and pressure to get our desired value.

Cont’ All components recovery in this plant are assumed with a value more than 0.9 to get highest efficiency The lower pressure of the refluxed absorber Is more than the higher Two Hypothetical group was added since polyethylbenzene and heavies is not available in component library

Multi compressors are used in series since increasing the pressure from 100 kpa to kpa cannot be done by one compressor. Same thing for valves used in series for decreasing from very high to low pressure. Recycled used to resolve the plant because of the difference between hysis and SRI.

4 sets of rxn is used to get more control on reactors process and products. Desired outlet stream of the plant =66162 and our outlet stream = kg/hr Number of units added = 17 unit The production of conversion reactor is more than equilibrium

Thank You For Your Attention