• Project plant life = 10 years after start-up
Specifically, you are to prepare the following by . . . (four weeks from now):
1. A written report detailing your design and profitability evaluation of the new process
2. A clear, complete, labeled process flow diagram of your optimized process
3. A clear stream flow table giving the T, P, total flowrate in kg/h and kmol/h, component
flowrate in kmol/h, and phase for each important process stream
4. A list of new equipment to be purchased, including size, cost, and materials of construction
5. An evaluation of the after-tax NPV, and the discounted cash flow rate of return on investment
(DCFROR) for your recommended (optimized) process
6. A legible, organized set of calculations justifying your recommendations, including any
assumptions made
C.4.4. Report Format
This report should be in the standard design report format. It should include an abstract, results,
discussion, conclusions, recommendations, and an appendix with calculations. The report format
rules given in Chapter 29 (in this CD) should be followed.
PROJECT 5. Problems at the Cumene Production Facility, Unit 800
C.5.1. Background
Cumene (isopropyl benzene) is produced by reacting propylene with benzene. During World War II,
cumene was used as an octane enhancer for piston engine aircraft fuel. Presently, most of the
worldwide supply of cumene is used as a raw material for phenol production. Typically, cumene is
produced at the same facility that manufactures phenol.
The plant at which you are employed currently manufactures cumene in Unit 800 by a vapor-phase
alkylation process that uses a phosphoric acid catalyst supported on kieselguhr. Plant capacity is on
the order of 90,000 metric tons per year of 99 wt% purity cumene. Benzene and propylene feeds are
brought in by tanker trucks and stored in tanks as a liquid.
C.5.2. Cumene Production Reactions
The reactions for cumene production from benzene and propylene are as follows:
C.5.3. Process Description
The PFD for the cumene production process, Unit 800, is given in Figure C.8. The reactants are fed
from their respective storage tanks. After being pumped up to the required pressure (dictated by
catalyst operating conditions), the reactants are mixed, vaporized, and heated in the fired heater to the
temperature required by the catalyst. The shell-and-tube reactor converts the reactants to desired and
undesired products as per the above reactions. The exothermic heat of reaction is removed by
producing high-pressure steam from boiler feed water in the reactor. The stream leaving the reactor
enters the flash unit, which consists of a heat exchanger and a flash drum. The flash unit is used to
separate the C3 impurities, which are used as fuel for a furnace in another on-site process. The liquid
stream from the flash drum is sent to the first distillation column, which separates benzene for
recycle. The second distillation column purifies cumene from the p-diisopropyl benzene (p-DIPB)
impurity. Currently, the waste p-DIPB is used as fuel for a furnace. The pressure of both distillation
columns is determined by the pressure in the flash drum; that is, there are no pressure-reduction
valves downstream of the flash drum.
Figure C.8. Process Flow Diagram for the Production of Cumene Process (Unit 800)
C.5.4. Recent Problems in Unit 800
Recently, Unit 800 has not been operating at standard conditions. We have recently switched
suppliers of propylene; however, our contract guarantees that the new propylene feed will be within
specifications given in Table C.13.
Upon examining present operating conditions, we have made the following observations:
1. Production of cumene has dropped by about 8%, and the reflux in T-801 was increased by
approximately 8% in order to maintain 99 wt% purity. The flows of benzene (Stream 5) and
propylene (Stream 2) remained the same. Pressure in the storage tanks has not changed
appreciably when measured at the same ambient temperature.
2. The amount of fuel gas being produced has increased significantly and is estimated to be 78%
greater than before. Additionally, it has been observed that the pressure control valve on the
fuel gas line (Stream 9) coming from V-802 is now fully open, although previously it was
controlling the flow.
3. The benzene recycle, Stream 11, has increased by about 5%, and the temperature of Stream 3
into P-801 has increased by about 3°C.
4. Production of steam in the reactor has fallen by about 6%.
5. Catalyst in the reactor was changed six months ago, and previous operating history (over last
ten years) indicates that no significant drop in catalyst activity should have occurred over this
time period.
6. p-DIPB production, Stream 14, has dropped by about 20%.
We are very concerned about this loss in production because we can currently sell all the material we
produce.
Another problem that has arisen lately is the malfunction of the feed pumps. This problem arose
during a very warm spell when the ambient temperature reached 110°F. A maintenance check showed
that P-802 needed a new bearing, and this was taken care of, but P-801 seemed to be OK. The
ambient temperature has now returned to a mild 70°F, and both pumps seem to be working fine.
Table C.13. Specifications of Products and Raw Materials
Currently, market conditions for cumene are very tight. We are in direct competition with some local
companies that have recently built cumene plants. It appears that management is very concerned about
our competitiveness because other producers in the area are beginning to undercut our prices.
Management wants to find out whether any significant savings in operating costs can be found for Unit
800.
C.5.5. Other Information
Other pertinent information is appended, including a flow table for the process streams at design
conditions, that is, prior to the current operating problem, Table C.14; a utility summary table at
design conditions, Table C.15; pump curves, Figures C.9 and C.10; a set of design calculations; and
an equipment list, Table C.16.
C.5.6. Assignment
Specifically, you are to prepare the following by . . . (two weeks from now):
1. A written report detailing your diagnosis of the operating problems with the plant, along with
your recommendations for solving these problems
2. A list of new equipment to be purchased, if any, including size, cost, and materials of
construction
3. An analysis of any change in the annual operating cost created by your recommended
modifications
4. A legible, organized set of calculations justifying your recommendations, including any
assumptions made
C.5.7. Report Format
This report should be brief. Most of the report should be an executive summary, not to exceed five
double-spaced, typed pages, which summarizes your diagnosis, recommendations, and rationale.
Figures and tables may be included (do not count these against the page limit) in the executive
summary. An appendix should be attached that includes items such as the requested calculations.
These calculations should be easy to follow. The guidelines given in Chapter 29 (in this CD) should
be followed.
Table C.14. Flow Summary Table for Cumene Production at Design Conditions, Unit 800
(Figure C.8)
Table C.15. Flow Summary Table for Utility Streams in Unit 800
Figure C.9. Pump, System, and NPSH Curves for P-801 A/B
Figure C.10. Pump, System, and NPSH Curves for P-802 A/B
Table C.16. Equipment Summary Table for Unit 800
C.5.8. Process Calculations
Calculations for Fuel Gas Exit Line for V-802
Design flow of fuel gas = 1192 kg/h
Molecular weight of fuel gas = 59.9
Gas viscosity = 9.5 × 10-6 kg/m.s
Gas density = 1.18 (273) P/(293 + 90) (1.01) = 0.00876P kg/m3 (P in bar)
Destination pressure (in burner in unit 900) = 1.25 bar
ΔPline + ΔPvalve = 1.75 – 1.25 = 0.50 bar
ΔPvalve should be ≅ 0.30 bar and ΔPline = 0.20 bar
Length of line (Stream 9A) ≅ 125 m (equivalent length including fittings)
Average pressure in line, P = (1.45 + 1.25) / 2 = 1.35 bar
Density of gas in line = 0.00876 P = 1.18 kg/m3
ΔPline = 2f ρu2Le/dpipe
Look at 3-in, 4-in, and 6-in schedule-40 pipe:
Choose 4-in schedule-40 pipe.
ΔPline = 0.152 bar and ΔPvalve = 0.50 – 0.152 = 0.348 bar
Calculations for P-801
Design Conditions (note that 1 kPa = 0.335 ft of water = 0.402 ft of benzene)
LAL (low alarm level) = 5 ft from ground and pump center line is 2 ft from ground
NOL (normal operating level) = 10 ft above ground level
NPSH Calculations (at LAL)
Static head = 5 – 2 = 3 ft of benzene = hstat
Psupply = 1.01 bar = 40.7 ft of benzene = hsupply
ΔPfriction (in supply line) = 1 psi = 2.8 ft of benzene = hfriction
Vapor Pressure of Stream 3
Vapor Pressure of Stream 3 = 0.74 bar @ 41°C = 29.7 ft of benzene = hvp
NPSHavailable = hsupply + hstatic – hfriction – hvp = 40.7 + 3 – 2.8 – 29.7 = 11.2 ft
NPSHrequired (from pump curve) = 6.1 ft @ 5.5 × 10-3 m3/s
∴ cavitation should not be a problem
System Curve Calculations
ΔPfriction (discharge) = 31.50 – 1.75 = 29.75 bar = 1196 ft of benzene
ΔPfriction (suction) = 2.8 ft of benzene
ΔPdischarge – tank = 1.75 – 1.01 = 0.74 bar = 30 ft of benzene
ΔPstatic = 0 (E-801 entrance @ 10 ft above ground level = NOL)
∴ Required head at design flow = 1199 + 30 + ΔPcv = 1230 ft of benzene + ΔPcv
From pump curve this gives us ΔPcv = 135 ft = 3.36 bar (this is high but OK)
Calculations for P-802
Design Conditions (note that 1 kPa = 0.335 ft of water = 0.666 ft of propylene)
LAL (low alarm level) = 10 ft from ground and pump center line is 2 ft from ground
NOL (normal operating level) = 20 ft from ground
NPSH Calculations (at LAL)
Static head = 10 - 2 = 8 ft of propylene = hstat
Psupply = Psat (@25°C) = 11.66 bar = 777 ft of propylene = hsupply
ΔPfriction (in supply line) = 0.2 psi = 1 ft of propylene = hfriction (3-in schedule 40 pipe
Le = 20 ft)
Vapor Pressure of Stream 2 = 11.66 bar = 777 ft of propylene = hvp
NPSHavailable = hsupply + hstatic – hfriction – hvp = 777 + 8 – 1 – 777 = 7 ft of propylene
(@ propylene flowrate of 2.57 × 10-3 m3/s)
NPSHrequired (from pump curve) = 6 ft
∴ cavitation should not be a problem (put note on P&ID to increase LAL to 12 ft to be safe)
System Curve Calculations
ΔPfriction (discharge) = 31.50 – 1.75 = 29.75 bar = 1981 ft of propylene
ΔPfriction (suction) = 1 ft of propylene
ΔPdischarge-tank = 1.75 – 11.66 = –9.91 bar = –660 ft of propylene
ΔPstatic = – 10 ft of propylene
∴ Required head at design flow = 1982 – 660 – 10 + ΔPcv = 1312 ft of propylene + ΔPcv
From pump curve this gives us ΔPcv = 140 ft = 2.10 bar
PROJECT 6. Design of a New, 100,000-Metric-Tons-per-Year Cumene
Production Facility
C.6.1. Background
In the opinion of our marketing research department, the demand for phenol-derived plasticizers is on
the rise. Therefore, we are investigating the possibility of a new, grass-roots phenol plant to handle
the anticipated increase. Because phenol is made from cumene, a grassroots cumene plant would also
be necessary. Given your experience in troubleshooting our existing cumene process, we would like
you to study the economics of a new cumene plant. Specifically, we would like a complete
preliminary design of a grassroots, 100,000 metric ton/y cumene process using benzene and
propylene.
We have a new, proprietary catalyst, and the kinetics are included in Table C.17. We would also like
you to consider the economics of our continuing to use propylene with 5% propane impurity at
$0.095/lb versus purer propylene feed. In preparing this preliminary design, you should assume that
all steam made can be used elsewhere in the plant with the appropriate economic credit, that
condensed steam can be returned as boiler feed water for the appropriate credit, and that fuel gas can
be burned for credit at its LHV (lower heating value). Additional information is given in Table C.18.
C.6.2. Assignment
Your assignment is to provide the following:
1. An optimized preliminary design of a plant to make cumene from benzene and propylene using
the new catalyst
2. An economic evaluation of your optimized process, using the following information:
• After-tax internal hurdle rate = 9% p.a.
• Depreciation = MACRS (6-year schedule; see Chapter 9)
• Marginal taxation rate = 35%
Table C.17 Reaction Kinetics for Cumene Reactions (Unit 800)
• Construction period = 2 years
• Project plant life = 10 years after start-up
Specifically, you are to prepare the following by . . . (four weeks from now):
1. A written report detailing your design and profitability evaluation of the new process
2. A clear, complete, labeled process flow diagram of your optimized process including all
equipment and the location of all major control loops
3. A clear stream flow table including T, P, total flowrate in kg/h and kmol/h, component flowrate
in kmol/h, and phase for each process stream
4. A list of new equipment to be purchased, including size, cost, and materials of construction
5. An evaluation of the annual operating cost for the plant
Table C.18 Additional Information (Unit 800)
6. An analysis of the after-tax NPV (10 years, 9%), and the discounted cash flow rate of return on
investment (DCFROR) for your recommended process
7. A legible, organized set of calculations justifying your recommendations, including any
assumptions made
C.6.3. Report Format
This report should be in the standard design report format, consistent with the guidelines given in
Chapter 29 (in this CD). It should include an abstract, results, discussion, conclusions,
