final gp2 process plantfor aromatic extraction

8/13/2019 Final GP2 Process Plantfor Aromatic Extraction

1/81

PROCESS PLANTFOR

AROMATIC SEPARATION

United Arab Emirates UniversityCollege of EngineeringTraining and Graduation Project UnitGraduation Project 2

ShahnazRomia

FatimaAmeri

ShaikhaNader

KhawlaKaabi


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ConclusionSafety Environmental impact

Cost AnalysisSite Selection

HAZOP and Safety Studies

Materials of ConstructionDetailed design

Summery of achievement in GP1 GP2

IntroductionAcknowledgments

Outline


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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.


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What are Aromatics ?Hydrocarbons with distinctive perfumed smell

Hydrogen

Carbon

Benzene

Toluene

Xylenes


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What is Aromatics Extract

Petroleum refining industry is the largest user o

Reformate

Rich in Benzene, Toluene and Xylenes (BTX).

Naphtha

Rich in aromatic hydrocarbons. Recovered from reformate stream by catalytic

treatment of lower boiling distillates.

Aromatics

Catalytic reforming of Naphtha. Extracted using suitable solvent.


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Summery of achievement in GP1 Designing a process plant for aromatics separationusing 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.


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Summery of achievement in GP2

Achievements in GP2:

Selecting the best types of pumps Detailed design of major pieces like heat exchangerscolumns Site selection for the aromatics extraction plant Materials of construction of the equipments HAZOP study was applied to each piece of equipment

Capital cost of the new aromatics extraction plant


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Detailed DesignDistillation

Used to separate key components in a mixture based on thedifference 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 andheat transfers between the liquid and vapor phases in the column.


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Cont./Detailed DesignStr ipper and Recovery Columns Using H YSYS

Number of trays 34

Column Diameter (m) 7.77

Column Height (m) 21Top composition

n-heptane Toluene Sulfolane 0.99 0.011 0

Bottom composition

n-heptane Toluene Sulfolane 0.00162 0.17 0.83

Number of trays 34

Column Diameter (m) 3.9

Column Height (m) 21Top composition

n-heptane Toluene Sulfolane 9.3*10 -3 0.99 0

Bottom composition

n-heptane Toluene Sulfolane 0 3.5*10 -5 0.99


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ab =

Using Antoine equation to calculate the vapor pressure:

vb

va

b

a

P P

K K

T C B

A P ln

T C B A P log

L av = ( (top) (bottom) )0.5 = 1.385

Cont./Detailed DesignStr ipper column hand calculation


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Cont./Detailed Design

2.28

385.1Log

0.17160.0016

0.01070.9893

Log= Nmin

avLog

X

X

X

X Log

= NminLW

HW

HD

LD

0562.0D

Lmin Rmin

18.044Lmin

0.01411

*XFXD

XFXD

=F

Lminavg

FB

DB

FA

DA

avg


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Assume R = 1.2 R minR = 0.0674

11

min

D

Dm D

R R R

f N

N N

0.011

D

Dm D

R

R R

58.63 N

0.511min

N N N

Using Gilliland correlation

32.5m1.8+1.2+0.51*)159(

*)1(

H

salloewance g Trayspacin N H act


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Cont./Detailed DesignRecovery column hand calcul ation

L av = ( (top) (bottom) )0.5 = 316.79

5 N

2* N

2.55= Nln

X-1X

X-1X

ln

N

ltheoritica

minltheoritica

min

B

B

D

D

min

N

avg

371.1*15.0

51.1*

thact

N N


16/81

Cont./Detailed Designm21.21.8+1.2+0.51*)17.36(

*)1(

H

salloewance g Trayspacin N H act

0183.0179.3164372523

1

min

min

RR

D F

RR

027.0022.05.12.1 min

RR RR RR

333)5(

237.15.1236336*

..

10*2057.8

14.92*37.0

mkg

m g

K K mole

matmmole

g atm

RT PMwt

v

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/m 3) =10.371m 3/s


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Comparison between HYSYS results and hand calculation

For stripper column For recovery column

HYSYS results Handcalculation

Nmin 34 59

Height (m) 21 32.5

Diameter(m) 7.7 7.7

m

V D 13.349.3

1.35-1.08*3.153*44

.

HYSYS results Handcalculation

Nmin 34 37

Height (m) 21 21.2

Diameter(m) 3.9 3.49

3.13


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Cont./Detailed DesignVessels

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


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Cont./Detailed DesignExtraction Column (T-101)

l d


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Cont./Detailed DesignLLE

l d


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Cont./Detailed DesignLLE

Mass balance of sulfolane (input streams)


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Cont./Detailed DesignPumps

Type of pump Maximum head (m)

Centrifugal pump 152

Axial pump 12

Rotary pump 15200

Reciprocating pump 300000

According to the value of the head, the pump type will be selected.

The expected maximum head for each type of pump

g P

H h g P

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


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For example, pump P101 A/BP1=1 bar to P 2= 8.83 bar.The density of the mixture is 848.5 kg/m 3

value of the head does not exceed 125m

068.94

81.95.848

10)183.8(

23

5

m

smmkg

Pa H


25/81


To find the power of the pump this equation was used:

Where: F is the head in feetG is the flow rate in gallon per minutes (gpm)

/(bar)Pr )min(67.13

Effeciencydropessurem FlowkW

104106.39-105.391038.21078.32855.080

221024

24274

G F G F F FG FG F Ef feciency


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The molecular weight of benzene is 78.11 kg/mol and for octane is 114.23 kg/

1min60)(

)hr kg(

3 hr mkg

mv

27.3138977.8189.383 hr

kg kmol

kg hr

kmol Mwnm avg

kmol kg Mwavg /77.81114.23)0.101()11.780.899(

min617.0

1min605.848

27.31389 3

3

m

hr mkg

hr kg

v

69.155137.0/1)(bar)-(8.83)min(.617067.13

kW m

Power

min1032.6

17.264

1min167.0

433 gallon

gallon

mm

feet308.62m1

feet3.28084068.94 m

%37.51 Effeciency


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Pumps

P in (bar)

P out (bar)

Head (m) Volumetric Flow rate(m 3 /min) Efficiency %

Power (kW)

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



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For our plant, shell and tube heat exchanger was chosen to transfer heat betweenfluids.

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 withstandshop fabrication stresses, shipping and field erection stresses and normaloperation conditions.

It can be easily cleaned and if failure occurs, elements such as tubes andgaskets can be easily replaced.

Cont./Detailed DesignH eat exchangers


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)()( ,,,.

,,,

.

out water inwater water P water out hinhh P oil T T C mT T C mq

C T bulk 4.68

28.3799

C kg J C C T At h P

obulk .

23934.68 ,

W skg

T T C mq hhh ph 905.183267)8.3799)(2393)(25.1()( 21,.

)( 21,.

ccc P c T T C mq

C C kg

J s

kg mW ooc )3045)(.4224)((905.183267

sec89.2 kg m c

Cont./Detailed DesignH eat exchangers


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Tc2=30 oC

Th2=37.8 oC

Tc1=45 oC

1

2

12

lnT T

T T T lm

Th1=99oC

T1= 54 oC

T2= 7.8 oC

C T C T o

o

8.7308.37544599

2

1

C T olm 88.23

2

2

2

17.0562

.450

28.7675

.450min

28.767588.23

905.183267

m

C m

W C

W

U UA

A

C mW U g assu

C W

C W

T q

UA

T UAq

o

o

o

oo

lm

lm

H eat exchangers


31/81

m L

Andp

m L g assu

1.08585*

17.0562

5min

From table A-11 (Holman, 2002) at nominal pipe size =1/8 in

tubesdp

ndpn

minOD

min ID

intube

tube

tube

159158.91910*833.6

1.0858,

010287.0405.0

10*833.6269.0

3

3

out shell dpn D *

inmdpn out 5.10690.1297010287.0*159*

H eat exchangers


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mdpnm D

min D

out shell

shell

1297.0*0.14633

0.146335.761

C T ob 4.68atmixturetheof Properties

:

sm

C mW k

mkg

o

27

w

3

1099.4m.s

kg0002528.0m.s

kg0003339.0.

1155.0918.6Pr

1.669

H eat exchangers


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lowturbulentf

sm

m sm

dpu

sm

mm

kg s

kg A

mu

Aum

mm

IDn A

in

crosstubes

crosstubes

tubecrosstubes

4392.661099.4

10*833.6*320806.0

*Re

0.3208060058299.0*1.669

25.1

*

**

0.0058299)10*832.6(*159*4

**4

27

3

23

,

.,

.

223

2,

14.0

3/18.0 Pr Re027.0

wd Nu

H eat exchangers


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14.0

3/18.0

sec.0002528.0

sec.0003339.0)918.6()4392.66(027.0

mkg

mkg

Nud

43.898 Nu

C mW

mC m

W

IDk Nu

h oo

tubein .

742.06810*833.6

.1155.0*43.898*

23

H eat exchangers


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559.4Pr sec109097.6

.6304.0

.1003.8.10862.6

096.993

27

4

4

3

mvC m

W k sm

kg sm

kg m

kg

o

w

Shell calculation:

C T b05.37

24530

C T b 5.37atwaterof PropertiesThe

H eat exchangers


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outshell

23

.

.

22222

22

dpn+d44

0.808550.0036023*096.993

89.2

*

**

0.0036023010287.0*159*40.14633*4

**4

*4

shell shell

shell

shell

tube shell shell

A P

A HD

smm

mkg

skg

Am

u

Aum

mmm

ODn D A

H eat exchangers


37/81

mmm

m HD 0.0025739

010287.0*159*0.14633*0.0036023*4 2

lowturbulentf

sm

m sm HDu

HD 3011.8410*9097.9

0.0025739*0.80855*Re 27

14.0

3/18.0 Pr Re027.0

wd Nu

14.0

4

4

3/18.0

sec.1003.8

sec.10862.6)559.4()3011.84(*027.0

mkg

mkg

Nu d

26.576d Nu

H eat exchangers


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C mW

mC m

W

HDk Nu

h oo

out .6509.168

0.0025739.

6304.0*26.576*2

C mW

C mW

C mW m

m

hhdpdp

U

o

oo

out inin

out

.458.185

.6509.168

1

.742.068*10*833.6

010287.01

1*

1

2

223

2

2

16.751

.458.185

28.7675m

C mW

C W

U UA A

o

o

Ldpn A intube

mm

mdpn A

Lin

908.410833.6**159

16.7513

2

H eat exchangers


39/81

The properties of this shell-and-tube heat exchanger (E-101)are:

skg m

C T C T

C T

C T s

kg m

water

oout water

oinwater

oh

oh

h

89.2

45308.37

99

25.1

.,

,

2

1

.

minOD

min IDtube

tube

010287.0405.0

10*833.6269.0 3

min D shell 0.146335.761

C mW U

m Atubesn

o.185.458

751.16159

2

2

m Length 908.4

H eat exchangers


40/81

The properties of heat exchangers E-102 are asfollows :

C T C T

C T C T

skg m

oout water

oinwater

oh

o

h

h

4530

46120

78.12

,

,

2

1

.

minODmin ID

tube

tube

010287.0405.010*833.6269.0 3

min D shell 0.07366900.2

C mW U

m Atubesn

o.298.21769

8657.227

2

2

m Length 944.4

H eat exchangers


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The properties of heat exchangers E-103 are as follows:

skg m

C T C T

C T C T

skg m

water

oout water

oinwater

oh

oh

h

4185.6

45308.37

63

27.8

.,

,

2

1

.

minODmin ID

tube

tube

010287.0405.010*833.6269.0 3

min D shell 0.247659.75

C mW U

m Atubesn

o.1108.23

085.30281

2

2

m Length 987.4

H eat exchangers


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43/81

Materials of construction (MOC)The selection of materials of construction for equipment and facilities to producechemicals is a core subject of chemical engineering.The desired products can not be manufactured without considering the selectionof optimum materials of construction used in the equipments of the process plantfor:

Safe. Economical manufacture. Required product quality.


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The selection of materials of construction is guided by several important pointssuch 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 becauseit is cheap and strong.

Extraction

column

Stripping

column

Raffinate

waterwash

column

Solvent

recoverycolumn

Water

Stripper

Solvent

regenerator

Stripper

receiver

Recovery

columnreceiver

Temperature(oC)

Top 99 118 37.8 63 110 177 46 63Bottom 85 168 37.8 169 121 - 46 63

Pressure(atm)

Top 6.10 1.88 5.08 0.37 1.41 0.68 1.41 0.37Bottom 8.83 2.22 5.08 0.59 1.48 - 1.41 0.37

Cont./ Materials of construction (MOC


45/81

Solvent regenerator reboiler which is constructed from stainless steel.

The reason behind this is that sulfolane is a very stable extraction solvent, butover time, and at high temperature in the presence of oxygen, it can formacidic compounds.



46/81

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


47/81

cinhout

cout hin

cinhout cout hin

T T T T

T T T T T

lnln

Total module cost for different areas

ln

ln

T U Q A

T UAQ

Cont./Detailed DesignOptimization of process vari ables


48/81

Exchangers Type ofExchanger

TubePressure

(barg)

MOC Area(squaremeters)

PurchasedEquipment

Cost

BareModule

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












Total module cost for different areas


49/81

Total module cost for different types of pumpsPumps

(with drives) Pump Type Power

(kilowatts) # Spares MOC Discharge

Pressure (barg) Purchased

Equipment Cost Bare Module Cost

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








P-101 Positive Displacement 15.7 1 Carbon Steel 8.83 $ 14,000 $ 53,000








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-105 Reciprocating 0.755 1 Carbon Steel 5.08 $ 13,600 $ 52,500



50/81

GuideWord

Deviation Possible Causes Consequences Actions Required

None No Flow - No feed materialbeing available.

- Outlet stream reduced- The temperature increases

causing damage.

- Install low level alarm.- Ensure good communication

with storage operator.

- Line Blockage,

Isolation valveclosed in error,LCV fails shut

- Outlet stream reduced- The temperature increases

causing damage.

- Check design of pump

strainers- Pipes maintenance- Installation for flow control.

- Line fracture - Outlet stream reduced- The temperature increases

causing damage.

- Covered by a)- Institute regular patrolling and

inspection of transfer line

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

Cont /HAZOP Study


51/81

Moreof

Flow - LCV fails or LCVbypass open inerror

- More Materialflow

- Low Outlet stream- It may overload

motor.

- Install high flow alarm(HFA) and check sizing ofrelief opposite liquid overfiling.

- Repair FCV

Pressure - Isolation valveclosed in error orLCV closed.

- Plug in pipe

Failure of MOC - Check lines and reducestroking speed of LCV idnecessary.

Temperature - TCV Failure

- Loss of coolingwater due topump failure

- Higherconsumption forcooling water inother unit whichdecrease thecooling water.

- High Temperaturein transfer line.

- Affects tensilestrength of MOC

- Plant shut down

- Install a high Temperaturealarm

- Repair TCV

- Do a circulation for the feedto avoid plant shutdownand do the maintenancemean while.

Lessof

Flow - FCV Failure

- Low material flow

- Leaking

- Material Loss- Low outlet stream

- Repair FCV

Cont./HAZOP Study


52/81

Cont./HAZOP Study Pressure - Inlet valve or suction line may be

clogged - Optimum condition not reached- MOC failure if vacuum reached- Causes cavitations which will damage

the component of the pump.- Great deal of noise.- Vibration and less of efficiency.

- Low pressure alarm(LPA)

- Maintain inlet valves

Temperature - TCV Failure - Plant shut down - Low Temperature Alarm (LTA)

- Decrease theprocessing flow rateto optimum rate

- Repair TCV Maintenance - Equipment Failure - Line cannot be completely drained or

purged - Install alarms.


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Cont./HAZOP Study Results of HAZOP for Extractor column T-101

Guide Word Deviation Possible Causes Consequences Actions

RequiredNone No Flow - No naphthafeed available

- The column may be washed by solvent, leaving fromthe bottom. (Quality and amount of product willsuffer)

- Install lowlevel alarm.

- No solvent flow - No separation of the naphtha feed - Install lowlevel alarm

- Line fracture - Accidental discharge to the environment (aromaticsare flammable material).

- Plant shutdown.

More of Flow - LCV fails openin error

- Erosion.- Overload the equipment.- Overfills- Material carry-over or inefficient separation.

- Furtherevaluation ofadditional cut-off valve andshutdown

system.


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Cont./HAZOP Study Pressure - Isolation valve close in

error - Failure of a vessel or the

associated piping leading tosequence events that result in a

disaster.- Other streams may be diverted

leading to spillage.

- Pressure relief device.- High pressure alarm (HPA)- Back up pump

- Maintain pipe

More flow ofsolvent

- Control valves fail open ortoo far open or misdirectedwhen on manual (FCVFailure).

- Action reversed orcontroller.

- More material flow

Decrease selectivity of the

separation.

- Install high level alarm andcheck sizing.

Temperature - Higher pressure in transfer

line- High miscibility.- TCV Failure

- Uncontrolled mixing of water withhydrocarbons which generatehigh pressure conditions causingdamage.

- The components present in themixture will flash to steam and

then can rupture pipes andvessels.

- Equip the system with pressurerelief device.

- High Temperature Alarm(HTA).

- Repair TCV.


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Cont./HAZOP Study

Less of Flow of solvent - Incorrect rate of process flows.

- FCV Failure.- Low material flow.

- Aromatic compoundsmay well be lost to theraffinate providing apure product butachieving a less thancomplete recovery.

- Isolate thatpart of theplant

- Repair FCV

Others Maintenance - Equipment Failure - Line cannot becompletely drained orpurged

- Install alarms.


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Cont./HAZOP Study Results of HAZOP for Water wash column V-101

Guide Word Deviation Possible Causes Consequences ActionsRequired

None Flow - No non-aromaticcompounds

- Water coming from stream 13

only pass through the

equipment

- low separation of non-aromatic

- Install lowlevel alarm

- Line fracture Accidental discharge to theenvironment.

- Plant shutdown.

More of More flow ofwater comingfrom recoverycolumn receiver

- LCV fails open in error - Overfills

- Water washes more material of

the non-aromatics

- Install highlevel alarmand checksizing.


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Cont./HAZOP Study Results of HAZOP for Stripper column T-102

Guide Word Deviation Possible Causes Consequences ActionsRequired

None No Flow - No flow in stream9 coming to thecolumn

- Quality and amount of product will suffer. - Install low levelalarm

- Line fracture - Accidental discharge to the environment(aromatics are flammable material).

- Plant shutdown.

More of Flow - LCV fails open inerror

- Overfills- Incomplete separation of non-aromatics from

solvent + aromatics

- Install highlevel alarm andcheck sizing.

Pressure - Isolation valveclose in error

- Full pump delivery - Isolation valveclose in error

Temperature - Higher pressure intransfer line

- Degradation of the solvent quality will becomesignificant ms.

- HighTemperature

Alarm (HTA).


58/81


59/81

Cont./HAZOP Study Results of HAZOP for Recovery column T-103

GuideWord

Deviation

Possible Causes Consequences Actions Required

None No Flow - No flow in stream 11 - No aromatic separation - Install low level alarm - Line fracture - Accidental discharge to the

environment - Plant shut down.

More of More flow ofsolvent richaromatics

- LCV fails open in error - Erosion.- Overload the equipment.- Leaks from other process.- .

- Install high level alarmand check sizing.

Pressure - Isolation valve close in

error

- Failure of a vessel or the associated

piping

- High pressure alarm

(HPA)- Back up pump

Temperature - Higher pressure intransfer line

- Degradation of the solvent whichleads to fouling and corrosionproblems.

- High Temperature Alarm(HTA).

- Repair TCV. Less of Flow - Leaking flange of valve

- Incorrect rate of processflows.

-FCV Failure.- Low material flow.

- Material discharge to theenvironment

- Isolate that part of theplant

- Repair FCV


60/81

Cont./HAZOP Study Results of HAZOP of Solvent regenerator V-104

Deviation Causes Consequences Action

More of Temperature - TCV Failure

- Solvent degradationcausing corrosion to theequipment.

- Equip the system with pressure reliefdevice.

- High Temperature Alarm (HTA).- Repair TCV.

Pressure - Blockage in some ofthe outlet streams.

- High flow in the inletstreams.

- Failure of a vessel or theassociated piping leading tosequence events that resultin a disaster.

- Pressure relief device.- High pressure alarm (HPA)- Back up pump- Maintain pipe

Flow - Control valves failopen or too far openor misdirected whenon manual (FCVFailure).

- Action reversed orcontroller.

- More material flow

- Erosion.- Overload the equipment.- Leaks from other process

streams or the environment.- Material carry-over or

inefficient separation.

- Further evaluation of additional cut-offvalve and shutdown system.

- Restriction orifice in line.

- High flow alarm (HFA)- Repair FCV


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Why J FZ Jafza is built over an area of 48

square kilometers, a fewkilometers from the city ofDubai. It ranks among theworlds largest and the fastestgrowing free zones.


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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.


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Manufacturing Cost


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FixedCapital

Investment

WasteTreatment

RawMaterial

s

OperatingLabor

Utilities

Maintenance

Manufacturing Cost

CAPCOST


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CAPCOSTThe CAPCOST program is used to determine the capital cost of differeitems of equipment in the process plant, which are heat exchangers, puvessels, extraction and distillation columns.

Pumps Power (KW) Discharge Pressure(barg) PurchasedEquipment Cost

Bare ModuleCost

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

Heat Exchangers Area (squaremeters) Purchased EquipmentCost Bare Module 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 pumps are centrifugal

All heat exchangers are multiple pipes and are centrifugal.

Cont./CAPCOST


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Cont./CAPCOST

All purchased towers are empty vertical vessel

Distillationcolumn

Height(meters)

Diameter(meters)

Pressure(barg)

PurchasedEquipment Cost

Bare ModuleCost

T-101 45 9 1 $ 2,350,000 $ 10,400,000

T-102 39 7.7 2.22 $ 1,490,000 $ 7,870,000T-103 21 3 0.59 $ 127,000 $ 515,000

Vessels Orientation Length/Height(meters)Diameter(meters)

Pressure(barg)

PurchasedEquipmentCost

Bare ModuleCost

V-101 Vertical 2.81 0.937 5.08 $ 5,750 $ 23,800

V-102 Horizontal 5.09 1.7 1.41 $ 15,200 $ 45,900V-103 Horizontal 4.34 1.44 0.37 $ 11,700 $ 35,200

Total purchased cost = $ 4,078,030


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Materials cost


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ate a s costSul folane cost

Sulfolane cost is equal to $4000/tones, where the total amount required inthe process is 6.228 tones/year.

Total cost of material = $4000/tones * 6.228 tones/year = 24,914.57$/yearMass of Sulfolane (Kg/hr) 0.068 Density of Sulfolane(Kg/m 3) 1261 (hr) 0.25

mass/density 0.000053 V(m3) 0.000013 annual purchase ($/yr) 0.00243

Cost of labor


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year 245shifts/ek.labor 5shifts/wear 49weeks/yer.labor shift /yeaof number

k.labor 5shift/week.labor shift /weeof number49weeks/labor work week of numbertotal

ar 52weeks/yeweek/year of numbertotal

4.47r yrear.labo245shifts/

/year 1095shiftsany timeat plantin theneededoperatorof number

/year 1095shiftsy3shifts/dar 365day/yeashift/year of numbertotal

3shift/day8hr/shift24hr/day

r sheft /yeaof number

year $

700,000year

$50,00014labor of cost

year $

50,000hour

$25

shiftshours

8year

shifts245hour working

14labor 13.284.472.97 Nol

2.97110.2331.7(0)6.29 Nol

equipmentof number N

handlingsolidof number P

labor of number Nol

N0.2331.7P6.29 Nol

2

np

2

np2

Profit Calculations


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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

year $700.365,817,991,ondepreciatiafter taxProfitCash

$25.751,487CostCapitalTotal0.1onDepreciatiyear

$949.105,817,503,taxtax beforeProfitafter taxProfityear

$27.987,375,454,12.0936,879,271,7ratetaxincome Nettax

year $936,879,271,7income Nettax beforeProfit

year $ 936,879,271,7COM-salefromIncomeincome Net

year $ 7275210336)62.2204*95.3(94.835438

($/tones) priceSelling(tones/yr)rateProductionsalefromIncome


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Safety Environmental impactHydrocarbon toxicity stands for toxic intake of either

petroleum or nonpetroleum-distillate hydrocarbons.

It has a considerable absorption through the humandigestive system causing:

Local toxicity (breathing problems, choking,

vomiting, cough, long term fever).Systemic toxicity (depression, euphoria, headache,dizziness and heart failure in severe cases).


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ConclusionThe objective was to design of a process plant that handles approximately37.89 m3/hr of an aromatic-rich blend of pyrolysis naphtha and coke ovenlight oil to separate aromatics such as benzene, toluene and xylenes by usingan aromatic-selective solvent (sulfolane).

Following missions were done: Material and energy balance, Design ofevery piece of equipment, Hazop study, safety and ethical considerations,cost analysis and the site selection.


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final gp2 process plantfor aromatic extraction

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