Report Mini Project Plant Design Ethylbenzene

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Report MINI Project Plant Design Ethylbenzene
Heat and Mass Transfer Laboratory (Universiti Teknologi MARA)
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FACULTY OF CHEMICAL ENGINEERING

UNIVERSITI TEKNOLOGI MARA SHAH ALAM
PLANT DESIGN AND ECONOMICS (CPE604)
TITLE:
PRODUCTION OF ETHYLBENZENE
PREPARED BY:
AHMAD ASYRAAF BIN SHAHRIZAMAN 2017632152

FATIN AQILAH BINTI ROSLI 2017631892
JOAN DOUMIN 2017631936
MOHAMAD HAKIM SYUWARI BIN HASAN 2017631996
NURUL HUSNA BINTI ABD AZIZ 2017631976
SITI NURAINI BINTI UDIN 2017632004
GROUP:
EH2205A & EH2205B (GROUP 2)
DATE OF SUBMISSION:
16 DECEMBER 2019
NAME OF LECTURER:
DR NORIN ZAMIAH BINTI KASSIM SHAARI

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TABLE OF CONTENTS
CHAPTER 1 (INTRODUCTION)
1.1 INTRODUCTION ........................................................................................................................ 3
1.2 PROPERTIES ............................................................................................................................... 3
1.2.1 PHYSICAL PROPERTIES ................................................................................................... 3
1.2.2 CHEMICAL PROPERTIES .................................................................................................. 4
1.3 PROCESS SELECTION............................................................................................................... 5
1.3.1 Liquid Phase Aluminium Chloride Catalyst: Friedel-Crafts/Alcar Process ............... 6
1.3.2 Vapour-Phase Zeolite Catalyst: Mobil/Badger Process ................................................ 7
1.3.3 Liquid Phase Zeolite Catalyst Process ............................................................................ 8
1.4 PROCESS DESCRIPTION ........................................................................................................ 11

1.5 PRODUCT SPECIFICATION AND DOWNSTREAM PROCESSING .................................. 12
1.6 REACTION KINETICS ............................................................................................................ 12
1.7 MARKET ANALYSIS .............................................................................................................. 15
1.6 SITE LOCATION ...................................................................................................................... 11
CHAPTER 2 (MASS AND ENERGY BALANCE)
2.1 STREAM TABLE....................................................................................................................... 22
2.2 MATERIAL BALANCE ............................................................................................................ 24
2.2.1 R-301 ................................................................................................................................. 25

2.2.2 R-302 .................................................................................................................................. 26
2.2.3 R-303 .................................................................................................................................. 27
2.2.4 V-302 ................................................................................................................................. 28

2.2.5 T-301 .................................................................................................................................. 29
2.2.6 T-302 .................................................................................................................................. 30
2.3 ENERGY BALANCE................................................................................................................. 31

2.3.1 R-301 ................................................................................................................................. 33
2.3.2 R-302 .................................................................................................................................. 41
2.3.3 R-303 .................................................................................................................................. 49
2.3.5 T-301 .................................................................................................................................. 57
2.3.5 T-302 .................................................................................................................................. 60
2.3.6 V-302 ................................................................................................................................. 63

CHAPTER 3 (PRELIMINARY DESIGN OF EQUIPMENT)
3.1 HEURISTIC FOR R-301 ............................................................................................................ 68
3.2 HEURISTIC FOR R-302 ............................................................................................................ 71

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3.3 HEURISTIC FOR R-303 ............................................................................................................ 74

3.4 HEURISTIC FOR V-302 ............................................................................................................ 77
3.5 HEURISTIC FOR T-301 ............................................................................................................ 86
3.6 HEURISTIC FOR T-302 ............................................................................................................ 91
CHAPTER 4 (COST CALCULATION)
4.1 COST OF BARE MODULE FOR EACH EQUIPMENT .......................................................... 96
4.1.1 HEAT EXCHANGER ..................................................................................................... 98

4.1.2 HEATER ......................................................................................................................... 110
4.1.3 PUMP ............................................................................................................................... 112
4.1.4 REACTOR ...................................................................................................................... 119

4.1.5 VESSEL .......................................................................................................................... 124
4.1.6 DISTILLATION COLUMN ........................................................................................ 132
4.3 COST OF MANUFACTURING PER YEAR .......................................................................... 140
4.3.1 COST OF UTILITIES ................................................................................................... 140

4.3.2 COST OF LABOR ......................................................................................................... 146
4.3.3 COST OF RAW MATERIAL ...................................................................................... 148
4.4 COST OF REVENUE ............................................................................................................... 150

4.5 LAND COST ............................................................................................................................ 151
4.6 COST OF MANUFACTURING SUMMARY ASSUMPTION .............................................. 152
CHAPTER 5 (PROFITABILITY ANALYSIS)
3.1 NON-DISCOUNTED & DISCOUNTED CASH FLOW ......................................................... 154
3.2 TAX RATE ............................................................................................................................... 155
3.3 SAMPLE OF CALCULATION ............................................................................................... 158
CHAPTER 6
6.0 CONCLUSION ......................................................................................................................... 159
REFERENCE .................................................................................................................................... 160

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CHAPTER 1: PROCESS BACKGROUND AND SELECTION
1.1 INTRODUCTION
Petrochemicals that turn oil and gas into all sorts of daily goods–such as plastics,
fertilizers, containers, clothes, digital devices, medical devices, detergents or tyres–are
essential to nowadays modern societies. Petrochemicals are also used in many aspects of the
renewable energy system, in addition to items that are important to our everyday lives, like
solar panels, wind turbine blades, batteries buildings thermal insulation and electric parts of
cars. Petrochemicals are rapidly becoming the largest consumption. One such most common
petrochemicals that is highly been produced widely is Ethylbenzene.
Ethylbenzene is an organic compound with the formula (C6H5CH2CH3) also known as

phenylethane, ethylbenzl or alpha-methyltoluene, a single ring and alkyl aromatic compound.
In petrochemical industry, the aromatic hydrocarbon is important and almost as an intermediate
in the production of styrene, which is used for making polystyrene, it is a common plastic
material. In styrene production, which uses ethylbenzene as a starting raw material, consumes
ca. 50% of the world’s benzene production. Less than 1% of the ethylbenzene produced is used
as paint solvent or as an intermediate to produce diethylbenzene and acetophenone.
(Ullmman''s, 1985)
It is used as a solvent for aluminium bromide in anhydrous electro deposition of

aluminium. Ethylbenzene is an ingredient in some paints and solvent grade xylene is nearly
always contaminated with a few per cent of ethylbenzene. (Vincent AVincent A. Welch, 2005)
1.2 PROPERTIES
1.2.1 PHYSICAL PROPERTIES
Under ordinary conditions, ethylbenzene is a clear, colourless liquid with a

characteristic aromatic odour which can be detected at low concentrations.
Ethylbenzene is an irritant to the skin and eyes. Moreover, it is moderately toxic
by ingestion, respiratory effects such as throat irritation and lung constriction,

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irritation to the eyes and skin adsorption. The physical properties of

ethylbenzene are as follows (Ullmman''s, 1985):
Table 1.1: Physical properties of Ethylbenzene
1.2.2 CHEMICAL PROPERTIES
Chemically, it is a monocyclic alkyl aromatic compound with a 106 of

molecular weight. It is miscible with most of the commonly used organic solvents in
any ratio but is only sparingly soluble in water (170 ppm under ambient conditions).
Spilled ethylbenzene will float on water and partition strongly towards air. No
significant environmental hazards are expected due to its high evaporation rate.
Being rather volatile and having a flash point of 19-23 °C, ethylbenzene is
classified as a highly flammable substance, which in use may form flammable or
explosive vapour-air mixtures. The most important commercial reaction of
Ethylbenzene is its dehydrogenation to styrene. The most important commercial
reaction of Ethylbenzene is its dehydrogenation to styrene. The reaction is carried out
at high temperature (600-660 0C) usually over an iron oxide catalyst. Steam is used as
diluents. Commercially, selectivity’s to styrene range from 89 to 96% with per-pass
conversions of 65-70%.

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The production by products is reduced if the temperature is gradually lowered

during the reaction. The hydro peroxide is subsequently reacted with propene in a
process that yields styrene and propylene oxide as co products. With suitable catalyst,
it can be converted to xylenes. Commercially processes for isomerising xylenes usually
involve the catalytic isomerisation or dealkylkylation of Ethylbenzene. Like toluene, it
may be dealkylated catalytically or thermally to benzene. It is also undergoing other
reaction typical of alkyl aromatic compounds. (Vincent AVincent A. Welch, 2005).
1.3 PROCESS SELECTION
Currently, almost all ethylbenzene is produced commercially by alkylating benzene

with ethylene. The chemical reaction to create ethyl benzene is:
𝐶6 𝐻6 + 𝐶2 𝐻4 → 𝐶6 𝐻5 𝐶𝐻2 𝐶𝐻3 Eq. (1.1)
Eq. (1.1) for the reaction of benzene and ethylene to form EB is accompanied by five side
reactions. Three of them are shown in Eq. (1.2), (1.3), and (1.4).
SIDE REACTION EQUATION
𝐶6 𝐻6 + 2𝐶2 𝐻4 → 𝐶6 𝐻4 (𝐶2 𝐻5 )2 1.2
𝐶6 𝐻5 𝐶𝐻2 𝐶𝐻3 + 𝐶2 𝐻4 → 𝐶6 𝐻4 (𝐶2 𝐻5 )2 1.3
𝐶6 𝐻6 + 𝐶6 𝐻4 (𝐶2 𝐻5 )2 → 2𝐶2 𝐻5 𝐶𝐻2 𝐶𝐻3 1.4
The reaction illustrated in Eq. (1.2) and (1.3) produces an undesired product, DEB. Proper use
of LeChatelier’s Principle can force the equilibrium reaction described by Eq. (1.4) to yield as
much desired product (EB) as possible.
Most production methods of creating ethyl benzene have approximately 95 mol% conversion.
The three methods discussed in this report include:
1) Liquid Phase Aluminium Chloride Catalyst: Friedel-Crafts/Alcar

Process
2) Vapour Phase Zeolite Catalyst: Mobil/Badger Process

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3) Liquid Phase Zeolite Catalyst Process
1.3.1 Liquid Phase Aluminium Chloride Catalyst: Friedel-Crafts/Alcar Process
One method of creating EB is through a Friedel-Crafts reaction of ethylene and

benzene in the presence of an aluminium chloride acid catalyst (AlCl3). This reaction
occurs in the liquid phase and is illustrated in Figure 1.1
Where,
R = Ethylene group
X = Chlorine atom
With this process, the AlCl3 is injected as fine particles into the alkylator reactor
where the ethyl benzene is formed. The AlCl3 is quite often promoted with HCl or
ethylene chloride to reduce the amount of AlCl3 required for the reaction. Once through
the reactor, the AlCl3 is filtered out of the product by water washing and then sent for
disposal or regeneration. To recover the unwanted diethylbenzene and other unwanted
products, a transalkylator is commonly used. Here, the unwanted products are
reconverted to EB, hence increasing feed conversion.
The liquid phase process has several advantages over the gas-phase process
because temperatures and pressures are reduced which lead to saving in operating costs.
In addition, the operation is safer since operating conditions are not as severe. Typical
running conditions for temperature and pressure are between 420-470 K and 70-150
psig for the alkylation and transalkylation processes. Another positive aspect of the
liquid phase reaction is that the catalyst is not subjected to high deactivation rates.
However, this type of catalyst does have some downfalls.
But the catalyst used in the AlCl3 process is an acid, which tends to corrode the
operating equipment unless the internals of the equipment are lined with special

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materials (such as brick or glass). The use of such materials increases construction costs
and may be expensive to maintain as some are quite fragile. In addition, the catalyst is
injected and removed from the process on a continuous basis, leading to higher
operation costs in water and filtration when the catalyst is separated from the process
stream. Finally, the AlCl3 catalyst is hazardous to the environment and there are
relatively high costs involved in assuring that it is stored and disposed of properly.
1.3.2 Vapour-Phase Zeolite Catalyst: Mobil/Badger Process
The vapour-phase reaction to create ethylbenzene using a zeolite catalyst is

referred to as the Mobil/Badger process. The mechanism for creating EB differs from
the AlCl3, since the zeolite catalyst produces a carbonium ion which activates the
ethylene to create an adsorbed electrophilic species which is quickly attacked by
benzene. This in turn causes a faster reaction; however, more by- 3 products are
produced which as well must be recycled and converted back to useful product using a
transalkylator.
Figure 1-2: Alkylation of Benzene and Ethylene to Form EB with Zeolite

Catalyst
Approximate operating conditions are 675-725 K and 200-400 psig. The

operating conditions are significantly higher than those for the liquid phase process,
resulting in higher risk and cost of operation.
Catalyst life using a gas-phase reaction is a major downfall of the gas-phase

process. The catalyst requires regeneration every two to four weeks. To maintain steady
state operation, it is typical to run two reactors in parallel. Because of this, the costs
associated with this process are high as shutdown costs, catalyst costs, and deactivated
catalyst disposal are high.

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The gas-phase reaction does have some positive aspects. The zeolite catalyst is
safer environmentally and disposal costs are not as high. Also, the catalyst is non-
corrosive and therefore special materials, which are required for the AlCl3 and Alcar
process, are not required. However, the catalyst life problem is a major issue with this
process. The AlCl3, Alcar, and liquid process using zeolite catalysts resolve this issue.
1.3.3 Liquid Phase Zeolite Catalyst Process
Like the Mobil/Badger process, the liquid phase reaction uses a zeolite catalyst
which does not require special material for reactor internals, piping, or in other parts of
the process. In addition, the zeolite catalyst is not as harmful to the environment which
saves in disposal costs.
This process, like the preceding AlCl3 and Alcar process, requires an alkylator
and a transalkylator. In addition, the operating temperature and pressures are like that
of the AlCl3 process. Since temperatures and pressures are not extreme there are large
savings available in operational costs when compared to the Mobil/Badger process.
The most positive aspect of this process is that catalyst life is claimed to be at
least five years for the alkylator and the transalkylator when using the EBZ-500™ and
EBZ-100™ as the catalyst, respectively. Also, these catalysts may be regenerated for
at least three cycles. Therefore, they constitute a more economical alternative to
conventional catalyst. Further savings are realized since shutdowns are less frequent to
change out the catalyst of the reactors.

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Table 1.2: The Comparison for Production Technology of Ethylbenzene. (Shenglin Liu, March 2009)
PROPERTIES LIQUID PHASE ALUMINIUM VAPOUR-PHASE ZEOLITE LIQUID-PHASE ZEOLITE

CHLORIDE ALKYLATION ALKYLATION ALKYLATION
OPERATING 420-470 K 675-725 K 420-470 K
TEMPERATURE
OPERATING 70-150 psig 200-400 psig 70-150 psig
PRESSURE
CONVERSION 99% 100% 100%
PHASE Three phases are present; Aromatic liquid, The high-activity catalyst allows The alkylation reactor is
ethylene gas, and a liquid catalyst complex transalkylation and alkylation to occur
maintained in liquid phase
phase simultaneously in a single reactor
CATALYST Aluminium Chloride Zeolite Catalyst Zeolite Catalyst
catalyst complex
ADVANTAGES i. The aluminium chloride present in i. Use of zeolite catalyst that i. The liquid phase zeolite catalyst
alkylation reactor effluent catalyst trans eliminated issues associated with process operates at substantially
alkylation reaction. corrosion and waste disposal and lower temperature decreased
ii. Reaction is very fast in the presence of waste side reactions dramatically
aluminium chloride & produce almost ii. The original vapour phase design resulting in ultra-high purity EB
stoichiometric yields of EB accomplished the alkylation and product

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transkylation reactions in single ii. The plant achieves high on-

reactor stream efficiency often greater
iii. The 3rd generation technology can than 99% which results in low
achieve EB yield greater than 99% turnaround & maintenance cost
iv. The 3rd generation technology iii. EBZ-500 catalyst has operating
offered significant benefits in length of more than 3 year
purity, capital cost without catalyst regeneration
DISADVANTAGES i. Handling and disposal of aluminium i. The significant extent of

chloride catalyst and waste has become isomerisation reactions and catalyst
increasingly more costly and deactivation by deposition of
complicated because of environmental carbonaceous material are most
considerations important problems associated with
ii. Equipment and piping corrosion and high temperature.
fouling along with related ii. The length of time between
environmental issues led to regeneration can vary from as little DO NOT HAVE DISADVANTAGES
development of EB process based on as 2 months to slightly more than 1
solid acid heterogeneous catalysts year depending on specific plant
design and operating conditions
iii. Because the reactors must be taken
off-line for regeneration, on-stream
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From above advantages & disadvantages for different processes we select Liquid-Phase
Zeolite Catalyst process. Since it has more advantages over other existing manufacturing
process for Ethylbenzene. Not only that, it also has long catalyst run length with excellent
stability which can minimizes plant downtime, and it has highly selective reaction that are
insignificant amount of by-products are produced, providing a highest product quality. Also, it
is less harm full to environment also. (technology, 2012).
1.4 PROCESS DESCRIPTION
The PFD for the EB process is shown in Figure 1-3. A refinery cut of benzene is fed
from storage to an on-site process vessel (V-301), where it was mixed with the recycled
benzene. From V-301, it was pumped to a reaction pressure of approximately 2000 kPa (20
atm) and sent to the fire heater (H-301) to bring it to reaction temperature (approximately
400oC). The preheated benzene was mixed with the feed ethylene just prior to entering the first
stage of a reactor system consisting three adiabatic packed bed reactors (R-301, R-302, R-303),
with interstage feed addition and cooling.
Reaction occurs in the gas phase and it is exothermic. The hot, partially converted
reactor effluent leaves the first packed bed, is mixed with more feed ethylene, and is fed into
E-301, where the stream is cooled to 380oC prior to passing to the second reactor (R-302),
where further reaction takes place. High-pressure steam is produced in E-301, and this steam
is subsequently used in the styrene unit. The effluent stream from R-302 is similarly mixed
with the feed ethylene and is cooled in E-302 (with generation of high-pressure steam) prior
entering the third and final packed bed reactor, R-303.
The effluent stream leaving the reactor contains products, by-products, unreacted
benzene and small amount of unreacted ethylene and other non-condensable gases. The reactor
effluent is cooled in two waste-heat boilers (E-303 and E-304), in which high-pressure and
low-pressure steam, respectively, is generated. This steam is also consumed in the styrene unit.
The two-phase mixture leaving E-304 is sent to a trim cooler (E-305), where the stream
is cooled to 80oC, and then to a two-phase separator (V-302), where the light gases are
separated and because of the high ethylene conversion, are sent overhead as fuel gas to be
consumed in the fired heater.
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The condensed liquid is then sent to benzene tower, T-301, where the unreacted
benzene is separated as the overhead product and returned to the front end of the process. The
bottom product from the first column is sent to T-302, where product EB is taken as the top
product and is sent directly to styrene unit. The bottom product form T-302 contains all DEB
and trace amount of higher ethylbenzenes.
This stream is mixed with recycle benzene and pass through the fired heater (H-301)
prior to being sent to a fourth packed-bed reactor (R-304), which the excess benzene is reacted
with DEB to produce EB and unreacted benzene. The effluent from this reactor is mixed with
the liquid stream entering the waste-heat boiler (E-303).
1.5 PRODUCT SPECIFICATION AND DOWNSTREAM PROCESSING
We have mentioned that ethyl benzene is a colourless liquid with a gasoline odour and
high inflammability. So that it is widely used in the petrochemical industry in manufacturing
of styrene. Styrene is used mostly important applications of ethylbenzene that were
manufactured in polymer production for polystyrene and mostly in polymer production for
polystyrene, acrylonitrile-butadiene-styrene (ABS) and styrene-acrylonitrile (SAN) resins,
styrene-butadiene elastomers and latexes, and unsaturated polyester resins. It is also used as an
intermediate material in the production of plastic products and is utilized as one of the basic
raw materials in the production of various chemicals. Ethylbenzene also a good solvent which
it has in different sectors like in the rubber industry, ink industry, the major markets of the
styrene ware include packaging, electrical/electronic/appliances, construction and consumer
products.
1.6 REACTION KINETICS
The production of EB takes place via the direct addition reaction between ethylene and
benzene:
𝐶6 𝐻6 + 𝐶2 𝐻4 → 𝐶6 𝐻5 𝐶𝐻2 𝐶𝐻3
benzene ethylene ethylbenzene Eq. (1.5)
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The reaction between EB and ethylene to produce DEB also takes place:
𝐶6 𝐻5 𝐶𝐻2 𝐶𝐻3 + 𝐶2 𝐻4 → 𝐶6 𝐻4 (𝐶2 𝐻5 )2

ethylbenzene ethylene diethylbenzene Eq. (1.6)
Additional reactions between DEB and ethylene yielding triethylbenzene (and higher) are also
possible. However, in order to minimize these additional reactions, the molar ratio of benzene
to ethylene is kept high, approximately at 8:1. The production of DEB is undesirable, and its
value as a side product is low. In addition, even small amounts of DEB and EB cause significant
processing problem in the downstream styrene process. Therefore, the maximum amount of
DEB in EB is specified as 2ppm. In order to maximize the production of EB, the DEB is
separated and returned to a separate reactor in which excess benzene is added to produce EB
via the following equilibrium reaction:
𝐶6 𝐻4 (𝐶2 𝐻5 )2 + 𝐶6 𝐻6 ⇌ 2𝐶6 𝐻5 𝐶2 𝐻5
diethylbenzene benzene ethylbenzene Eq. (1.7)
The incoming benzene contains a small amount of toluene impurity. The toluene reacts with
ethylene to form EB and propylene:
toluene ethylene ethylbenzene propylene Eq. (1.8)
𝐶6 𝐻5 𝐶𝐻3 + 2𝐶2 𝐻4 ⇌ 𝐶6 𝐻5 𝐶2 𝐻5 + 𝐶3 𝐻6
The reaction kinetics derived for a new catalyst are given as
𝐸𝑖
−𝑟𝑖 = 𝑘𝑜,𝑖 𝑒 −𝑅𝑇 𝐶𝑒𝑡ℎ𝑦𝑙𝑒𝑛𝑒
𝑎 𝑏
𝐶𝐸𝐵 𝑐
𝐶𝑡𝑜𝑙𝑢𝑒𝑛𝑒 𝑑
𝐶𝑏𝑒𝑛𝑧𝑒𝑛𝑒 𝑒
𝐶𝐷𝐸𝐵
Where i is the reaction number above Eq. (1.i) and the following relationships pertain:
i Ei (kcal/mol) Ko,i a b c d e
5 22500 1.00 × 106 1 0 0 1 0
6 22500 6.00 × 105 1 1 0 0 0
7 25000 7.80 × 106 0 0 0 1 1
8 20000 3.80 × 108 2 0 1 0 0
The unit of ri are kmol/s/m3 - reactor, the units of Ci are kmol/m3 -gas, and the unit of k vary
depending upon the form of the equation.
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Figure 1-3: The Process Flow Diagram (PFD) of Ethylbenzene Production
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1.7 MARKET ANALYSIS
The global Ethylbenzene market is growing at a fast pace due to high demand in global
industry. The production of Ethylbenzene market has a very good potential in the global
business. Ethylbenzene is produced by the alkylation of benzene with ethylene in the presence
of alumina chloride or zeolite catalyst. It is a colourless liquid which is highly flammable. The
production of styrene monomer is the most important application of Ethylbenzene, which is
mainly consumed in production of plastics, on its own in homopolymers such as polystyrene
(PS) and expandable polystyrene (EPS). Other use of Ethylbenzene is in anti-knocking agents,
diethyl benzene, solvent in paints and natural gas recovery. The global Ethylbenzene market is
projected to reach $23.45 M by 2021. (BusinessWire, 2017).
Figure 1.7-1: Ethylbenzene Market, Revenue (%), by Application, Global; 2018
Styrene Production to Dominate the Market

Styrene production have a positive influence on ethylbenzene market demand. The
styrene-based polymers, elastomers, and resins have a wide range of applications in various
end-user industries, such as electronics, packaging, agriculture, petrochemicals, and
construction. Expandable polystyrene beads are used in food and beverage packaging, cushion
packaging and insulation. Enhanced grades of resins are used in higher performance
applications, including home electronics and appliances. (mordorintelligence.com, 2019)
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Global Ethylbenzene Supply and Demand
Figure 1.7-2: World Supply/Demand for Ethylbenzene-2008 (thousands of metric tons)
Figure 1.7-3: Global Ethylbenzene Demand Analysis (Sample)
Asia-Pacific leads in the consumption of Ethylbenzene and continues to be the major

volume contributor due to strong styrene demand while Western Europe and North America
together accounted for 35% of global Ethylbenzene production. (Prismanceconsulting.com,
2019). The Asia-Pacific region covers for more than half of global Ethylbenzene demand and
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was the largest market for Ethylbenzene in 2011, with 53% of the global demand share. A large
portion of Ethylbenzene demand in the Asia-Pacific region comes from China, which held
around 28% of regional demand. (BusinessWire,2012). Asia-Pacific is forecast to grow at
much higher rate due to the major growth in China which is estimated to be more than 8%
annually. The global ethylbenzene and styrene market are expected to grow at about 2% to
2.5% per year during the forecast period. (Industry data analytics, 2018)
Year 2008
Production Capacity of Ethylbenzene 35.1 million metric tons

Global Demand of Ethylbenzene 27.6 million metric tons
Year 2013
Production Capacity of Ethylbenzene 38.2 million metric tons

Global Demand of Ethylbenzene 31.7 million metric tons
Demand growth rate (2008-2013) 2.9%
(Davis, 2009)
Ethylbenzene Production by Region, Country
Figure 1.7-4: Ethylbenzene Market – Growth Rate by Region, 2019-2024
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The Asia-Pacific region dominated the global market share in 2018. The usage of
Ethylbenzene has been increasing in the China, India and Japan due to the growing construction
and packaging industries, application as solvent and reagents or coating in paints, including
dye and synthetic rubber. In January 2018, construction of a USD 6.8 billion crude oil refinery
and petrochemical complex commenced in Barmer, Rajasthan, India by Hindustan Petroleum
Corporation Limited (HPCL) and Rajasthan Refinery Limited (HRRL).
(mordorintelligence.com, 2019). The construction sector is expected to record a moderate pace
growth over the next five years due to the increasing investments in public infrastructure,
renewable energy, infrastructure, and commercial projects.
Figure 1.7-5: Ethylbenzene Market Value, 2015-2021 ($ Million)
Figure 1.7-6: World consumption of Ethylbenzene in 2017
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United States, Western Europe and China are the world’s largest ethylbenzene
producing regions. United States, Western Europe and China’s production share of
Ethylbenzene are 5.5 M, 6.8 M and 6.7 M metric tons in 2013. The global production capacity
of ethylbenzene is forecast to experience a considerable growth, from around 39 million metric
tons in 2018 to approximately 48 million metric tons in 2023. (M. Garside, 2019)
1.8 PLANT PRODUCTION CAPACITY
From a report done from CEH estimates by Sean Davis, 2009, it is recorded that the
annual capacity in the mid-2009 is about 228,000 metric tons, produced by Idemitsu SM (Pasir
Gudang, Malaysia). Idemitsu’s Pasir Gudang facility in Malaysia will boost its capacity by
2010 bringing its total to 260,000 metric tons. From this source, we can scale-up the production
of the plant up until about this value. A scale-up by 3 is done on the original production
capacity, which results in 240,000 tons per year for our plant production capacity, as shown
below;
80,000 tonnes/year x 3.0 = 240,000 tonnes/year
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1.9 SITE LOCATION
In order to build plant design for production of ethylbenzene, the place to begin with is
very important aspect to look for. The location proposed for our production of ethylbenzene
are Kerteh, Butterworth and Pasir Gudang. There are few things need to be considered to locate
the plant. Each of this location will be evaluated using concept scoring and screening method
which will be discussed below.
Concept Screening
Criterion Kerteh Butterworth Pasir Gudang
Raw Material 0 0 +
Marketing 0 0 +
Transportation 0 0 0
Water Supply + 0 +
Waste Disposal 0 0 0
Tax & Legal 0 0 0
restriction
Total score 1 0 3
Rank 2 3 1
Concept Scoring
Criterion Weight Kerteh Pasir Gudang
Raw Material 35% 3 5
Marketing 20% 3 5
Transportation 15% 4 4
Water Supply 20% 4 3
Waste Disposal 5% 5 5
Tax & Legal 5% 3 3
restriction
Total score 3.45 4.35
Rank 2 1
20

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In terms of transportation, Pasir Gudang is more accessible because it is connected to highway

that headed to North Peninsular Malaysia. This allows the product to be transport and sell
across Malaysia. Same goes to Kerteh and Butterworth since it also accessible to roads and
highway that links to major towns and other states. In Pasir Gudang, it is easier to obtain raw
material from supplier. It is because it is well-known chemical manufacturing production
industry. At Pasir Gudang, for production of ethylbenzene, there are no competition in
marketing and its high demands around that industrial area. Kerteh, Terengganu is the best
option since the price of water is the lowest compared to the other states. However, we still
choose Pasir Gudang, Johor due to the fact that other factors on site selection prefer more
towards the state.
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CHAPTER 2: MASS AND ENERGY BALANCE
2.1 STREAM TABLE
Table 2.1: Flow Summary Table for the process shown in Figure 1-3
Stream
Number 1 2 3 4 5 6 7 8 9 10 11 12
Pressure (kPa) 110 2000 110 2000 2000 1985 1970 1960 1945 2000 1935 1920
Temperature
(°C) 25.0 25.0 58.5 25.0 25.0 383.3 444.1 380.0 453.4 25.0 380.0 449.2
Vapor Fraction 0.0 1.0 0.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Mass Flow
(kg/h) 23283.9 8458.5 53856.6 2537.7 2960.4 56393.7 56393.7 59354.1 59354.1 2960.4 62314.5 62314.5
Mole Flow
777.63
(kmol/h) 297 300.03 687.63 90 105.04 701.52 807.03 709.118 105.04 814.118 654.39
Component
Flowrate
Ethylene 0 279 0 83.7 97.65 83.7 2.55 100.2 1.86 97.65 99.51 1.62
Ethane 0 21 0 6.3 7.35 6.3 6.3 13.65 13.65 7.35 21 21
Propylene 0 0 0 0 0 0 5.49 5.43 6 0 6 6
Benzene 291 0 679.53 0 0 679.53 611.73 611.73 524.88 0 524.88 445.02
Toluene 6 0 6 0 0 6 6 0.57 0.0078 0 0.0078 0
Ethylbenzene 0 0 2.1 0 0 2.1 72.84 72.84 149.85 0 149.85 149.85
1,4-
2.61 2.61 12.87 12.87 30.9
DiEthBenzene 0 0 0 0 0 0 0
22

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Stream Number 13 14 15 16 17 18 19 20 21 22 23
Pressure (kPa) 1988 1920 110 110 105 120 110 140 2000 2000 2000
Temperature (°C) 497.9 458.1 73.6 73.6 81.4 145.4 139 191.1 82.6 82.6 121.4
Vapor Fraction 1.00 1.00 1.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Mass Flow (kg/h) 13846.5 76163.7 3126 73037.7 39964.5 33073.5 28615.8 4457.7 30572.7 9391.8 1384.5
Mole Flow (kmol/h) 153.783 870.03 55.929 814.05 510.45 303.45 269.67 101.34 390.6 120 153.75
Component Flowrate
Ethylene 0 1.62 1.62 0 0 0 0 0 0 0 0
Ethane 0 21 21 0 0 0 0 0 0 0 0
Propylene 0 6 6 0 0 0 0 0 0 0 0
Benzene 88.5 533.55 25.14 274.62 507.69 0.51 0.51 0 388.53 119.34 119.34
Toluene 0 0 0 0 0 0 0 0 0 0 0
Ethylbenzene 65.07 276.75 2.13 508.38 2.76 271.89 269.16 2.73 2.1 0.66 3.36
1,4-DiEthBenzene 0.213 31.11 0.039 31.05 0 31.05 0.0003 31.05 0 0 31.05
23

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2.2 MATERIAL BALANCE
General equation for material balance:
Input – Output + Generation – Consumption = Accumulation
For continuous processes at steady state, the accumulation term equal to zero. There are no
chemical reaction takes place. There also no generation and no consumption. Hence, the
material balance equation for non-reactive system is simplifying to:
Input = Output
Assumptions:
1. the system is operating at steady state. Thus, there is no accumulation.
2. Reasonably high conversion in the reactors.
3. Effects of side reactions minimal.
For Reactive System:
Material balance equation for reactive system is simplifying to:
Input + Generation = Output + Consumption
𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 𝑖𝑛𝑝𝑢𝑡 𝑡𝑜 𝑝𝑟𝑜𝑐𝑒𝑠𝑠−𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 𝑜𝑢𝑡𝑝𝑢𝑡 𝑓𝑟𝑜𝑚 𝑝𝑟𝑜𝑐𝑒𝑠𝑠

Overall conversion =
𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 𝑖𝑛𝑝𝑢𝑡 𝑡𝑜 𝑝𝑟𝑜𝑐𝑒𝑠𝑠
𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 𝑖𝑛𝑝𝑢𝑡 𝑡𝑜 𝑟𝑒𝑎𝑐𝑡𝑜𝑟−𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 𝑜𝑢𝑡𝑝𝑢𝑡 𝑓𝑟𝑜𝑚 𝑟𝑒𝑎𝑐𝑡𝑜𝑟

Single-Pass Conversion =
𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 𝑖𝑛𝑝𝑢𝑡 𝑡𝑜 𝑟𝑒𝑎𝑐𝑡𝑜𝑟
𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑑𝑒𝑠𝑖𝑟𝑒𝑑 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑓𝑜𝑟𝑚𝑒𝑑

Yield = 𝑚𝑜𝑙𝑒𝑠 𝑡ℎ𝑎𝑡 𝑤𝑜𝑢𝑙𝑑 ℎ𝑎𝑣𝑒 𝑏𝑒𝑒𝑛 𝑓𝑜𝑟𝑚𝑒𝑑 𝑖𝑓 𝑡ℎ𝑒𝑟𝑒 𝑤𝑒𝑟𝑒 𝑛𝑜 𝑠𝑖𝑑𝑒 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛𝑠 𝑎𝑛𝑑
𝑡ℎ𝑒 𝑙𝑖𝑚𝑖𝑡𝑖𝑛𝑔 𝑟𝑒𝑎𝑐𝑡𝑎𝑛𝑡 ℎ𝑎𝑑 𝑟𝑒𝑎𝑐𝑡𝑒𝑑 𝑐𝑜𝑚𝑝𝑙𝑒𝑡𝑒𝑙𝑦
𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑑𝑒𝑠𝑖𝑟𝑒𝑑 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑓𝑜𝑟𝑚𝑒𝑑

Selectivity =
𝑚𝑜𝑙𝑒𝑠 𝑜𝑓 𝑢𝑛𝑑𝑒𝑠𝑖𝑟𝑒𝑑 𝑝𝑟𝑜𝑑𝑢𝑐𝑡 𝑓𝑜𝑟𝑚𝑒𝑑
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MATERIAL BALANCE FOR MAJOR EQUIPMENTS
2.2.1 Reactor 1 (R-301)
Input Output
Component Molar Composition Component Molar Composition
Flow Flow Rate
Rate (kmol/hr)
(kmol/hr)
Ethylene (C2H4) 83.7 0.1076 Ethylene (C2H4) 2.55 0.0036
Ethane (C2H6) 6.30 0.0081 Ethane (C2H6) 6.30 0.0089
Benzene (C6H6) 679.53 0.8738 Propylene (C3H6) 5.49 0.0078
Toluene (C7H8) 6.00 0.0077 Toluene (C7H8) 6.00 0.0086
Ethylbenzene 2.1 0.0027 Benzene (C6H6) 611.73 0.8720

(C6H5CH2CH3)
Ethylbenzene 72.84 0.1038
(C6H5CH2CH3)
1,4- 2.61 0.0037

Diethylbenzene
(C10H14)
Total 777.63 1.0000 Total 701.52 1.0000
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2.2.2 Reactor 2 (R-302)
Input Output
Flow Flow Rate
Rate (kmol/hr)
(kmol/hr)
Ethylene (C2H4) 100.20 0.1242 Ethylene (C2H4) 1.86 0.0026
Ethane (C2H6) 13.65 0.0169 Ethane (C2H6) 13.65 0.0192
Propylene (C3H6) 5.43 0.0067 Propylene (C3H6) 6.00 0.0085
Benzene (C6H6) 611.73 0.7580 Benzene (C6H6) 524.88 0.7402
Toluene (C7H8) 0.57 0.0007 Toluene (C7H8) 0.0078 0
Ethylbenzene 72.84 0.0903 Ethylbenzene 149.85 0.2113

(C6H5CH2CH3) (C6H5CH2CH3)
1,4- 2.61 0.0032 1,4- 12.87 0.0182

Diethylbenzene Diethylbenzene
(C10H14) (C10H14)
Total 807.03 1.0000 Total 709.1178 1.0000
26

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2.2.3 Reactor 3 (R-303)
Input Output
Flow Flow
Rate Rate
(kmol/hr) (kmol/hr)
Ethylene (C2H4) 1.62 0.0019 Vapor
Ethane (C2H6) 21.00 0.0241 Ethylene (C2H4) 1.62 0.0290
Propylene (C3H6) 6.00 0.0069 Ethane (C2H6) 21.00 0.3755

(C6H5CH2CH3)
1,4- 31.11 0.0357 Ethylbenzene 2.13 0.0381
Diethylbenzene (C6H5CH2CH3)
(C10H14)
Total 870.03 1.0000 1,4- 0.039 0.0006
Diethylbenzene
(C10H14)
Total 55.929 1
Liquid
Benzene (C6H6) 274.62 0.3374

(C6H5CH2CH3)
1,4- 31.05 0.0381
Diethylbenzene
(C10H14)
Total 814.05 1
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2.2.4 Separator (V-302)
Input Output
Flow Flow
Rate Rate
(kmol/hr) (kmol/hr)
Ethylene (C2H4) 1.62 0.0019 Vapor
Ethane (C2H6) 21.00 0.0241 Ethylene (C2H4) 1.62 0.0290
Propylene (C3H6) 6.00 0.0069 Ethane (C2H6) 21.00 0.3755

(C6H5CH2CH3)
1,4- 31.11 0.0357 Ethylbenzene 2.13 0.0381
Diethylbenzene (C6H5CH2CH3)
(C10H14)
Total 870.03 1.0000 1,4- 0.039 0.0006
Diethylbenzene
(C10H14)
Total 55.929 1
Liquid
Benzene (C6H6) 274.62 0.3374

(C6H5CH2CH3)
1,4- 31.05 0.0381
Diethylbenzene
(C10H14)
Total 814.05 1
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2.2.5 Distillation Column 1 (T-301)
Input Output
Flow Flow
Rate Rate
(kmol/hr) (kmol/hr)
Ethylbenzene 274.62 0.3374 Distillate
(C6H5CH2CH3)
Benzene (C6H6) 508.38 0.6245 Ethylbenzene 2.76 0.0054
(C6H5CH2CH3)
1,4- 31.05 0.0381 Benzene (C6H6) 507.69 0.9946
Diethylbenzene
(C10H14)
Total 510.45 1
Bottom

(C6H5CH2CH3)
Benzene (C6H6) 0.51 0.0017
1,4- 31.05 0.1023

Diethylbenzene
(C10H14)
Total 814.05 1 Total 303.45 1
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2.2.6 DISTILLATION COLUMN 2 (T-302)
Input Output
Flow Flow
Rate Rate
(kmol/hr) (kmol/hr)
Ethylbenzene 271.89 0.8960 Distillate
(C6H5CH2CH3)
Benzene (C6H6) 0.51 0.0017 Ethylbenzene 269.16 0.9981
(C6H5CH2CH3)
1,4- 31.05 0.1023 Benzene (C6H6) 0.51 0.0018
Diethylbenzene
(C10H14)
1,4- 0.0003 0.0001
Diethylbenzene
(C10H14)
Total 269.6703 1
Bottom

(C6H5CH2CH3)
1,4- 31.05 0.9731
Diethylbenzene
(C10H14)
Total 303.45 1 Total 101.34 1
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2.3 ENERGY BALANCE

METHODS IN DETERMINATION OF ENERGY BALANCE
• Find the enthalpy change with to the respect reference condition

Href (gas,liquid), To , 1 atm---˃ Hfinal (gas,liquid), Tf, P kPa
⩟ 𝐻 = 𝐻2 - 𝐻1
• Use Hess’ Law
- Summation of enthalpy change for each single path process is
equivalent to enthalpy change in overall process path
⩟ 𝐻𝑜𝑣𝑒𝑟𝑎𝑙𝑙 = ∑⩟ 𝐻𝑖
Type of single path process state
Enthalpy change for constant pressure process,

- Use heat integration of heat capacity function
𝑇𝑓𝑖𝑛𝑎𝑙 𝑇𝑓
⩟H = ∫𝑇𝑟𝑒𝑓 𝐶𝑝 𝑑𝑇 = ∫𝑇𝑜 𝐴 + 𝐵𝑇 + 𝐶𝑇 2 + 𝐷𝑇 3 𝑑𝑇
- Use heat integration of heat capacity at average temperature

𝑇𝑓𝑖𝑛𝑎𝑙
- ⩟H = ∫𝑇𝑟𝑒𝑓 𝐶𝑝@𝑇 𝑎𝑣𝑔 𝑑𝑇 Where T avg = 𝑇1 +2 𝑇 2
-Use integration of heat capacity (Kopp’s Rule)
For gas phase reaction processes,

Enthalpy changes for isothermal compression, Constant T
(Assuming ideal gas) ( PV=constant)
𝑉2 1
⩟H = ∫ 𝑃dv = RT∫𝑉1 dV
𝑉
𝑉2
= RT ln ( )
𝑉1
𝑃1
= RT ln ( ) Where P1 x V1 = P2 x V2
𝑃2
Assumptions in calculation
1)The open system at steady state
2) No moving parts in the system
3) The linear velocities of all streams at single height.
4) The effects of pressure will be neglect if the pressure of the system under 30 atm.
5)The heat of formation for certain substances will be neglected since the limitation
of physical properties data.
6) All the physical and chemical properties of substances was refer from
Perry’s Chemical Engineer’s Handbook, Perry, R.H. and Elementary Chemical Process.
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General Energy Balance Equation
Q−W=∆ H+ ∆ E k + ∆ E p
Based on the assumptions stated above,
W= 0 , ∆ E k= 0 , ∆ E p =0
Therefore, the equation can be reduced to
Q = ∆ H
Equation for reactive system:

Qnet = ∑ 𝑛𝑖,𝑜𝑢𝑡 𝐻𝑖,𝑜𝑢𝑡 − ∑ 𝑛𝑖,𝑜𝑢𝑡 𝐻𝑖,𝑜𝑢𝑡
Hi= Ht + Hf
Equation for non-reactive system:

Qnet = ∑ 𝑛𝑖,𝑜𝑢𝑡 𝐻𝑖,𝑜𝑢𝑡 − ∑ 𝑛𝑖,𝑜𝑢𝑡 𝐻𝑖,𝑜𝑢𝑡
32

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2.3.1 Energy Balance R-301
∆Hin ∆Hout
T = 383.3°C T = 444.1℃
P = 1985 kPa R-301 P = 1970 kPa
Energy balance:
∆H = ∑𝒐𝒖𝒕𝒍𝒆𝒕 𝒏𝒊 (∆Ĥ) − ∑𝒊𝒏𝒍𝒆𝒕 𝒏𝒊 (∆Ĥ)
Reference state: C (Ɩ) and H (Ɩ) at 383.3℃ and 1 atm
Inlet Outlet
Substances nin
Ĥin (kJ/mol) Ĥin nout Ĥout
Ĥ8
(kmol/h) (kJ/mol) (kmol/h) (kJ/mol)
Benzene
679.53 113.027 Ĥ1 611.73 122.0700 Ĥ9
(C6H6)
Ethyl benzene
2.1 84.4032 Ĥ2 72.84 100.0080 Ĥ10
(C8H10)
1,4-
Diethylbenze
ne 0 119.746 Ĥ3 2.61 142.35 Ĥ11
(C10H14)
Propylene
0 46.0800 Ĥ4 5.49 17.6966 Ĥ12
(C3H6)
Ethane
6.3 10.5820 Ĥ5 6.3 15.05 Ĥ13
(C2H6)
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Ethylene
83.7 57.836 Ĥ6 2.55 61.0969 Ĥ14
(C2H4)
Toluene
6 90.509 Ĥ7 6 101.7768 Ĥ8
C6H5CH3
∑ 𝒏𝒊 (∆Ĥ)82428.8778 83288.676
∑ 𝒏𝒊 (∆Ĥ)
𝒊𝒏𝒍𝒆𝒕
3 𝒐𝒖𝒕𝒍𝒆𝒕
55
For inlet stream:

Href (g),25°C, 1atm –˃ H#a (g),383.3°C, 1atm ---˃H#b(g), 383.3°C, 1985 kPa
Benzene
Ĥ1f = 82.93 kJ/mol
Cp = 74.06x10-3 + 32.96x10-5T- 25.2x10-8T + 77.57x10-12T3 = 276 J/mol.℃)
383.3
Ĥ1a = ∫25 74.06𝑥10−3 + 32.96𝑥10−5 𝑇 − 25.2𝑥10−8 𝑇 2 + 77.57𝑥10 − 12𝑇 3 𝑑𝑇
= 46.3344 𝑘𝐽/𝑚𝑜𝑙
𝑃1
Ĥ1b =𝑅𝑇 ln( )
𝑃2
= (8.3145x10-3)(656.45) ln(101.325/1985) 𝑘𝐽/𝑚𝑜𝑙

= −16.237 𝑘𝐽/𝑚𝑜𝑙
Ĥ1= 82.93 + 46.3344 -16.237 = 113.027 𝑘𝐽/𝑚𝑜𝑙
Ethylbenzene
Ĥ2f = 29.79 kJ/mol
(25+273.15)+(449.2+273.15)
Tavg = 2
=475.575 𝐾
Cp @ T avg (C8H10) = 197.74 J/mol.℃
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383.3
Ĥ2a = ∫25 197.74 𝑑𝑇
= 70.85 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(656.45) ln(101.325/1985) 𝑘𝐽/𝑚𝑜𝑙

= −16.237 𝑘𝐽/𝑚𝑜𝑙
Ĥ2= 29.79 + 70.85 -16.237 = 84.4032 𝑘𝐽/𝑚𝑜𝑙

1,4-diethylbenzene
Ĥ3f = -20.34 kJ/mol
Ĥ3 ref = −556.52 kJ/kg

= −74.697 𝑘𝐽/𝑚𝑜𝑙
Ĥ3 a= 487.2 𝑘𝐽/𝑘𝑔
= 65.391 𝑘𝐽/𝑚𝑜𝑙
Ĥ3 = -20.34 + 64.391 - (-74.697) = 119.746 𝑘𝐽/𝑚𝑜𝑙
Propylene
Ĥ4f = 29.79 kJ/mol
Cp = 59.58x10-3 + 17.71x10-5T- 10.17x10-8T + 24.6x10-12T3 (J/mol.℃)
383.3
Ĥ4a = ∫25 59.58𝑥10−3 + 17.71𝑥10−5 𝑇 − 10.17𝑥10−8 𝑇 2 + 24.6𝑥10−12 𝑇 3 𝑑𝑇
= 32.526 𝑘𝐽/𝑚𝑜𝑙
𝑃1
Ĥ4b =𝑅𝑇 ln(𝑃2)
= (8.3145x10-3)(656.45) ln(101.325/1985) 𝑘𝐽/𝑚𝑜𝑙
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lOMoARcPSD|8481882
= −16.237 𝑘𝐽/𝑚𝑜𝑙
Ĥ4= 29.79 + 32.15 −17.792 = 46.08 𝑘𝐽/𝑚𝑜𝑙
Ethane
Cp = 49.37x10-3 + 13.92x10-5T- 5.816x10-8T + 7.28 x10-12T3 ( J/mol.℃)

383.3
Ĥ5a = ∫25 49.37𝑥10−3 + 13.9210−5 𝑇 − 5.816𝑥10−8 𝑇 2 + 7.28𝑥10−12 𝑇 3 𝑑𝑇
= 26.819 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(656.45) ln(101.325/1985) 𝑘𝐽/𝑚𝑜𝑙

= −16.237 𝑘𝐽/𝑚𝑜𝑙
Ĥ5= 26.5 -17.792 = 10.582 𝑘𝐽/𝑚𝑜𝑙
Ethylene
Ĥ6f = 52.28 kJ/mol
Cp = 40.75x10-3 + 11.47x10-5T- 6.891x10-8T + 17.66 x10-12T3 (J/mol.℃)
383.3
Ĥ6a = ∫25 40.75𝑥10−3 + 11.47 𝑥 10−5 𝑇 − 6.891𝑥10−8 𝑇 2 + 17.66 𝑥10−12 𝑇 3 𝑑𝑇
= 21.793 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(656.45) ln(101.325/1985) 𝑘𝐽/𝑚𝑜𝑙

= −16.237 𝑘𝐽/𝑚𝑜𝑙
36

lOMoARcPSD|8481882
Ĥ6= 52.28 + 21.54 -17.792 = 57.836 𝑘𝐽/𝑚𝑜𝑙
Toluene
Ĥ7f = 50.0 kJ/mol
Cp = 94.18x10-3 + 38x10-5T- 27.86 x10-8T + 80.33 x10-12T3 (J/mol.℃)
383.3
Ĥ7a = ∫25 94.18 𝑥10−3 + 38 𝑥 10−5 𝑇 − 27.86𝑥10−8 𝑇 2 + 80.33 𝑥10−12 𝑇 3 𝑑𝑇
= 56.0746 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(656.45) ln(101.325/1985) 𝑘𝐽/𝑚𝑜𝑙

= −16.237 𝑘𝐽/𝑚𝑜𝑙
Ĥ7= 50.0 + 26.92 -17.792 = 90.509 𝑘𝐽/𝑚𝑜𝑙
For outlet stream:

Benzene
Ĥ8f = 82.93 kJ/mol
Cp = 74.06x10-3 + 32.96x10-5T- 25.2x10-8T + 77.57x10-12T3 = 276 J/mol.℃)
444.1
Ĥ8a = ∫25 74.06𝑥10−3 + 32.96𝑥10−5 𝑇 − 25.2𝑥10−8 − 8𝑇 2 + 77.57𝑥10 − 12𝑇 3 3 𝑑𝑇
= 56.8365 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(717.25) ln(101.325/1970) 𝑘𝐽/𝑚𝑜𝑙

= −17.6966 𝑘𝐽/𝑚𝑜𝑙
Ĥ8= 82.93 + 56.8365 −17.6966 = 122.07 𝑘𝐽/𝑚𝑜𝑙
37

lOMoARcPSD|8481882
Ethylbenzene
Ĥ9f = 29.79 kJ/mol
(25+273.15)+(449.2+273.15)
Tavg = 2
=510.25 𝐾
Cp @ T avg (C8H10) = 209.77 J/mol.℃

444.1
Ĥ9a = ∫25 209.77 𝑑𝑇
= 87.9146 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(717.25) ln(101.325/1970) 𝑘𝐽/𝑚𝑜𝑙

= −17.6966 𝑘𝐽/𝑚𝑜𝑙
Ĥ9= 29.79 + 87.9146 -17.6966 = 100.008 𝑘𝐽/𝑚𝑜𝑙
Href (g),25°C, 1atm –˃ H#final(g), 444.1°C, 1970 kPa
1,4-diethylbenzene
Ĥ10f = -20.34 kJ/mol
Ĥ10 ref = −556.52 kJ/kg

= −74.697 𝑘𝐽/𝑚𝑜𝑙
Ĥ10 final= 655.6229 𝑘𝐽/𝑘𝑔
= 91.5065 𝑘𝐽/𝑚𝑜𝑙
Ĥ10 = -20.34 + 91.5065 - (-74.697) = 142.35 𝑘𝐽/𝑚𝑜𝑙
38

lOMoARcPSD|8481882
Propylene
Ĥ11f = 29.79 kJ/mol
Cp = 59.58x10-3 + 17.71x10-5T- 10.17x10-8T + 24.6x10-12T3 = 276 J/mol.℃)
444.1
Ĥ11a = ∫25 59.58𝑥10−3 + 17.71𝑥10−5 𝑇 − 10.17𝑥10−8 𝑇 2 + 24.6𝑥10−12 𝑇 3 3 𝑑𝑇
= 36.65 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(717.25) ln(101.325/1970) 𝑘𝐽/𝑚𝑜𝑙

= −17.6966 𝑘𝐽/𝑚𝑜𝑙
Ĥ11= 29.79 + 36.65 −17.6966 = 51.743 𝑘𝐽/𝑚𝑜𝑙
Ethane
Cp = 49.37x10-3 + 13.92x10-5T- 5.816x10-8T + 7.28 x10-12T3 = 276 J/mol.℃)

444.1
Ĥ12a = ∫25 49.37𝑥10−3 + 13.92x10−5 𝑇 − 5.816𝑥10−8 𝑇 2 + 7.28𝑥10−12 𝑇 3 3 𝑑𝑇
= 32.7474 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(717.25) ln(101.325/1970) 𝑘𝐽/𝑚𝑜𝑙

= −17.6966 𝑘𝐽/𝑚𝑜𝑙
Ĥ12= 32.7474 -17.7458 = 15.05 𝑘𝐽/𝑚𝑜𝑙
39

lOMoARcPSD|8481882
Ethylene
Ĥ13f = 52.28 kJ/mol
Cp = 40.75x10-3 + 11.47x10-5T- 6.891x10-8T + 17.66 x10-12T3 = 276 J/mol.℃)
444.1
Ĥ13a = ∫25 40.75𝑥10−3 + 11.47 𝑥 10−5 𝑇 − 6.891𝑥10−8 𝑇 2 + 17.66 𝑥10−12 𝑇 3 3 𝑑𝑇
= 26.5135 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(717.25) ln(101.325/1970) 𝑘𝐽/𝑚𝑜𝑙

= −17.6966 𝑘𝐽/𝑚𝑜𝑙
Ĥ13= 52.28 + 26.92 -17.6681 = 61.0969 𝑘𝐽/𝑚𝑜𝑙
Toluene
Ĥ14f = 50.0 kJ/mol
Cp = 94.18x10-3 + 38x10-5T- 27.86 x10-8T + 80.33 x10-12T3 = 276 J/mol.℃)
444.1
Ĥ14a = ∫25 94.18 𝑥10−3 + 38 𝑥 10−5 𝑇 − 27.86𝑥10−8 𝑇 2 + 80.33 𝑥10−12 𝑇 3 3 𝑑𝑇
= 69.4734 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(717.25) ln(101.325/1970) 𝑘𝐽/𝑚𝑜𝑙

= −17.6966 𝑘𝐽/𝑚𝑜𝑙
Ĥ14= 50.0 + 26.92 -17.7458 = 101.7768 𝑘𝐽/𝑚𝑜𝑙
𝑄 = ∑ 𝑛𝑜𝑢𝑡 Ĥ𝑜𝑢𝑡 − ∑ 𝑛𝑖𝑛 Ĥ𝑖𝑛
= [83288.67655−82428.87783 ] 𝑀𝐽/ℎ
=859.798719𝑀𝐽/ℎ
=238.83 kW
40

lOMoARcPSD|8481882
2.3.2 Energy Balance R-302
∆Hin ∆Hout
T = 380.0°C T = 453.4℃
P = 1960 kPa R-302 P = 1945 kPa
Energy balance:
Inlet Outlet
Substances nin Ĥin (kJ/mol)

Ĥout
nout (kmol/h)
(kmol/h) (kJ/mol)
Benzene
611.73 110.913 Ĥ1 524.88 123.6683 Ĥ8
(C6H6)
Ethyl benzene
72.84 82.196 Ĥ2 149.85 95.3514 Ĥ9
(C8H10)
1,4-
Diethylbenzene
2.61 118.62 Ĥ3 12.87 145.86 Ĥ10
(C10H14)
Propylene
5.43 44.148 Ĥ4 6 52.86 Ĥ11
(C3H6)
Ethane
13.65 8.708 Ĥ5 13.65 15.9313 Ĥ12
(C2H6)
Ethylene
100.2 56.028 Ĥ6 1.86 61.6931 Ĥ13
(C2H4)
41

lOMoARcPSD|8481882
Toluene
0.57 59.128 Ĥ7 0.0078 103.7342 Ĥ14
C6H5CH3
∑ 𝒏𝒊 (∆Ĥ) 80151.86073 ∑ 𝒏𝒊 (∆Ĥ) 81726.82

𝒊𝒏𝒍𝒆𝒕 𝒐𝒖𝒕𝒍𝒆𝒕
333
Reference state: C (Ɩ) and H (Ɩ) at 380 ℃ and 1960 kPa

For inlet stream:
Href (g),25°C, 1atm –˃ H#a (g),380°C, 1atm ---˃H#b(g), 380°C, 1960 kPa
Benzene
Ĥ1f = 82.93 kJ/mol
Cp = 74.06x10-3 + 32.96x10-5T- 25.2x10-8T + 77.57x10-12T3 = 276 J/mol.℃)
380
Ĥ1a = ∫25 4.06𝑥10−3 + 32.96𝑥10−5 𝑇 − 25.2𝑥10−8 − 8𝑇 2 + 77.57𝑥10 − 12𝑇 3 3 𝑑𝑇
= 45.775 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(722.35) ln(101.325/1960) 𝑘𝐽/𝑚𝑜𝑙

= −17.792 𝑘𝐽/𝑚𝑜𝑙
Ĥ1= 82.93 + 45.775 -16.018 = 110.913 𝑘𝐽/𝑚𝑜𝑙
Ethylbenzene
Ĥ2f = 29.79 kJ/mol
(25+273.15)+(449.2+273.15)
Tavg = 2
=475.575 𝐾
Cp @ T avg (C8H10) = 197.74 J/mol.℃

380
Ĥ2a = ∫25 197.74 𝑑𝑇
= 70.198 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
42

lOMoARcPSD|8481882
= (8.3145x10-3)(722.35) ln(101.325/1960) 𝑘𝐽/𝑚𝑜𝑙

= −17.792 𝑘𝐽/𝑚𝑜𝑙
Ĥ2= 29.79 + 70.198 -17.792 = 82.196 𝑘𝐽/𝑚𝑜𝑙

Href (g),25°C, 1atm –˃ H#final(g), 380°C, 1960 kPa
1,4-diethylbenzene
Ĥ3f = -20.34 kJ/mol
Ĥ3 ref = −556.52 kJ/kg

= −74.697 𝑘𝐽/𝑚𝑜𝑙
Ĥ3 a= 478.828 𝑘𝐽/𝑘𝑔
= 64.2673 𝑘𝐽/𝑚𝑜𝑙
Ĥ3 = -20.34 + 64.391 - (-74.697) = 118.62 𝑘𝐽/𝑚𝑜𝑙
Propylene
Ĥ4f = 29.79 kJ/mol
Cp = 159.58x10-3 + 17.71x10-5T- 10.17x10-8T + 24.6x10-12T3 (J/mol.℃)
449.2
Ĥ4a = ∫25 59.58𝑥10−3 + 17.71𝑥10−5 𝑇 − 10.17𝑥10−8 𝑇 2 + 24.6𝑥10−12 𝑇 3 𝑑𝑇
= 32.15 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(722.35) ln(101.325/1960) 𝑘𝐽/𝑚𝑜𝑙

= −17.792 𝑘𝐽/𝑚𝑜𝑙
Ĥ4= 29.79 + 32.15 −17.792 = 44.148 𝑘𝐽/𝑚𝑜𝑙
43

lOMoARcPSD|8481882
Ethane
Cp = 49.37x10-3 + 13.92x10-5T- 5.816x10-8T + 7.28 x10-12T3 ( J/mol.℃)

449.2
Ĥ5a = ∫25 49.37𝑥10−3 + 13.9210−5 𝑇 − 5.816𝑥10−8 𝑇 2 + 7.28𝑥10−12 𝑇 3 3 𝑑𝑇
= 26.5 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(722.35) ln(101.325/1960) 𝑘𝐽/𝑚𝑜𝑙

= −17.792 𝑘𝐽/𝑚𝑜𝑙
Ĥ5= 26.5 -17.792 = 8.708 𝑘𝐽/𝑚𝑜𝑙
Ethylene
Ĥ6f = 52.28 kJ/mol
Cp (C8H10) = 40.75x10-3 + 11.47x10-5T- 6.891x10-8T + 17.66 x10-12T3 = 276 J/mol.℃)
449.2
Ĥ6a = ∫25 40.75𝑥10−3 + 11.47 𝑥 10−5 𝑇 − 6.891𝑥10−8 𝑇 2 + 17.66 𝑥10−12 𝑇 3 3 𝑑𝑇
= 21.54 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(722.35) ln(101.325/1960) 𝑘𝐽/𝑚𝑜𝑙

= −17.792 𝑘𝐽/𝑚𝑜𝑙
Ĥ6= 52.28 + 21.54 -17.792 = 56.028 𝑘𝐽/𝑚𝑜𝑙
44

lOMoARcPSD|8481882
Toluene
Ĥ7f = 50.0 kJ/mol
Cp = 94.18x10-3 + 38x10-5T- 27.86 x10-8T + 80.33 x10-12T3 (J/mol.℃)
380
Ĥ7a = ∫25 94.18 𝑥10−3 + 38 𝑥 10−5 𝑇 − 27.86𝑥10−8 𝑇 2 + 80.33 𝑥10−12 𝑇 3 3 𝑑𝑇
= 56.076 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(722.35) ln(101.325/1960) 𝑘𝐽/𝑚𝑜𝑙

= −17.792 𝑘𝐽/𝑚𝑜𝑙
Ĥ7= 50.0 + 26.92 -17.792 = 59.128 𝑘𝐽/𝑚𝑜𝑙
For outlet stream:

Benzene
Ĥ8f = 82.93 kJ/mol
Cp = 74.06x10-3 + 32.96x10-5T- 25.2x10-8T + 77.57x10-12T3 = 276 J/mol.℃)
453.4
Ĥ8a = ∫25 4.06𝑥10−3 + 32.96𝑥10−5 𝑇 − 25.2𝑥10−8 − 8𝑇 2 + 77.57𝑥10 − 12𝑇 3 3 𝑑𝑇
= 58.4841 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(726.55) ln(101.325/1945) 𝑘𝐽/𝑚𝑜𝑙

= −17.7458 𝑘𝐽/𝑚𝑜𝑙
Ĥ8= 82.93 + 58.4841 −17.7458= 123.6683 𝑘𝐽/𝑚𝑜𝑙
45

lOMoARcPSD|8481882
Ethylbenzene
Ĥ9f = 29.79 kJ/mol
(25+273.15)+(449.2+273.15)
Tavg = 2
=510.25 𝐾
Cp @ T avg (C8H10) = 209.77 J/mol.℃

453.4
Ĥ9a = ∫25 209.77 𝑑𝑇
= 83.3072 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(726.55) ln(101.325/1945) 𝑘𝐽/𝑚𝑜𝑙

= −17.7458 𝑘𝐽/𝑚𝑜𝑙
Ĥ9= 29.79 + 83.3072 -17.6681 = 95.3514 𝑘𝐽/𝑚𝑜𝑙
1,4-diethylbenzene
Ĥ3f = -20.34 kJ/mol
Ĥ3 ref = −556.52 kJ/kg
= −74.697 𝑘𝐽/𝑚𝑜𝑙
= 91.5065 𝑘𝐽/𝑚𝑜𝑙
Ĥ3 = -20.34 + 91.5065 - (-74.697) = 145.86 𝑘𝐽/𝑚𝑜𝑙

Propylene
Ĥ4f = 29.79 kJ/mol
Cp = 159.58x10-3 + 17.71x10-5T- 10.17x10-8T + 24.6x10-12T3 = 276 J/mol.℃)
453.4
Ĥ4a = ∫25 59.58𝑥10−3 + 17.71𝑥10−5 𝑇 − 10.17𝑥10−8 𝑇 2 + 24.6𝑥10−12 𝑇 3 3 𝑑𝑇
46

lOMoARcPSD|8481882
= 40.8185 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(726.55) ln(101.325/1945) 𝑘𝐽/𝑚𝑜𝑙

= −17.7458 𝑘𝐽/𝑚𝑜𝑙
Ĥ4= 29.79 + 40.8185 −17.7458 = 52.86 𝑘𝐽/𝑚𝑜𝑙
Ethane
Cp = 49.37x10-3 + 13.92x10-5T- 5.816x10-8T + 7.28 x10-12T3 = 276 J/mol.℃)

453.4
Ĥ5a = ∫25 49.37𝑥10−3 + 13.9210−5 𝑇 − 5.816𝑥10−8 𝑇 2 + 7.28𝑥10−12 𝑇 3 3 𝑑𝑇
= 33.6771 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(726.55) ln(101.325/1945) 𝑘𝐽/𝑚𝑜𝑙

= −17.7458 𝑘𝐽/𝑚𝑜𝑙
Ĥ5= 33.6771 -17.7458 = 15.9313 𝑘𝐽/𝑚𝑜𝑙
Ethylene
Ĥ6f = 52.28 kJ/mol
Cp = 40.75x10-3 + 11.47x10-5T- 6.891x10-8T + 17.66 x10-12T3 = 276 J/mol.℃)
453.4
Ĥ6a = ∫25 40.75𝑥10−3 + 11.47 𝑥 10−5 𝑇 − 6.891𝑥10−8 𝑇 2 + 17.66 𝑥10−12 𝑇 3 3 𝑑𝑇
= 27.1589 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
47

lOMoARcPSD|8481882
= (8.3145x10-3)(726.55) ln(101.325/1945) 𝑘𝐽/𝑚𝑜𝑙

= −17.7458 𝑘𝐽/𝑚𝑜𝑙
Ĥ6= 52.28 + 26.92 -17.6681 = 61.6931 𝑘𝐽/𝑚𝑜𝑙
Toluene
Ĥ7f = 50.0 kJ/mol
Cp = 94.18x10-3 + 38x10-5T- 27.86 x10-8T + 80.33 x10-12T3 = 276 J/mol.℃)
453.4
Ĥ7a = ∫25 94.18 𝑥10−3 + 38 𝑥 10−5 𝑇 − 27.86𝑥10−8 𝑇 2 + 80.33 𝑥10−12 𝑇 3 3 𝑑𝑇
= 71.48 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(726.55) ln(101.325/1945) 𝑘𝐽/𝑚𝑜𝑙

= −17.7458 𝑘𝐽/𝑚𝑜𝑙
Ĥ7= 50.0 + 26.92 -17.7458 = 103.7342 𝑘𝐽/𝑚𝑜𝑙
= [81726.82−80151.86] 𝑀𝐽/ℎ
= 1574.963 𝑀𝐽/ℎ
= 437.49 kW
48

lOMoARcPSD|8481882
2.3.3 Energy Balance(R-303)
∆Hin ∆Hout
T = 380.0°C T = 449.2℃
P = 1935 kPa R-303 P = 1920 kPa
Energy balance:
Inlet Outlet
Substances
Ĥin (kJ/mol) Ĥin
nin (kmol/h) nout (kmol/h) Ĥout (kJ/mol)
(kJ/mol)
Ĥ8
Benzene
445.02 112.687 Ĥ1 524.88 123.0357
(C6H6)
Ethyl benzene Ĥ9
106.065 83.97 Ĥ2 149.85 101.106
(C8H10)
1,4- Ĥ10
Diethylbenzene
30.9 118.718 Ĥ3 12.87 144.37
(C10H14)
Propylene Ĥ11
6 45.922 Ĥ4 6 52.386
(C3H6)
Ethane Ĥ12
21 10.482 Ĥ5 21 15.7826
(C2H6)
Ethylene Ĥ13
1.62 63.182 Ĥ6 99.51 61.5319
(C2H4)
49

lOMoARcPSD|8481882
Toluene 0.0078 90.058 Ĥ14

Ĥ7 0 -
C6H5CH3
63321.34428 88356.54419
∑ 𝒏𝒊 (∆Ĥ) ∑ 𝒏𝒊 (∆Ĥ)
𝒊𝒏𝒍𝒆𝒕 𝒐𝒖𝒕𝒍𝒆𝒕
Reference state: C (Ɩ) and H (Ɩ) at 25℃ and 1 atm

For inlet stream:
Benzene
Ĥ1f = 82.93 kJ/mol
Cp = 74.06x10-3 + 32.96x10-5T- 25.2x10-8T + 77.57x10-12T3 ( J/mol.℃)
380
Ĥ1a = ∫25 74.06𝑥10−3 + 32.96𝑥10−5 𝑇 − 25.2𝑥10−8 − 8𝑇 2 + 77.57𝑥10 − 12𝑇 3 3 𝑑𝑇
= 45.775 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(722.35) ln(101.325/1935) 𝑘𝐽/𝑚𝑜𝑙

= −16.018 𝑘𝐽/𝑚𝑜𝑙
Ĥ1= 82.93 + 45.775 -16.018 = 112.687 𝑘𝐽/𝑚𝑜𝑙
Ethylbenzene
Ĥ2f = 29.79 kJ/mol
(25+273.15)+(449.2+273.15)
Tavg = 2
=475.575 𝐾
Cp @ T avg (C8H10) = 197.74 J/mol.℃

380
Ĥ2a = ∫25 197.74 𝑑𝑇
= 70.198 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
50

lOMoARcPSD|8481882
= (8.3145x10-3)(722.35) ln(101.325/1935) 𝑘𝐽/𝑚𝑜𝑙

= −16.018 𝑘𝐽/𝑚𝑜𝑙
Ĥ2= 29.79 + 70.198 -16.018 = 83.97 𝑘𝐽/𝑚𝑜𝑙
Href (g),25°C, 1atm –˃ H#final(g), 380°C, 1935 kPa
1,4-diethylbenzene
Ĥ3f = -20.34 kJ/mol
Ĥ3 ref = −556.52 kJ/kg

= −74.697 𝑘𝐽/𝑚𝑜𝑙
= 64.391 𝑘𝐽/𝑚𝑜𝑙
Ĥ3 = -20.34 + 64.391 - (-74.697) = 118.718 𝑘𝐽/𝑚𝑜𝑙
Propylene
Ĥ4f = 29.79 kJ/mol
Cp = 159.58x10-3 + 17.71x10-5T- 10.17x10-8T + 24.6x10-12T3 ( J/mol.℃)
449.2
Ĥ4a = ∫25 59.58𝑥10−3 + 17.71𝑥10−5 𝑇 − 10.17𝑥10−8 𝑇 2 + 24.6𝑥10−12 𝑇 3 3 𝑑𝑇
= 32.15 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(722.35) ln(101.325/1935) 𝑘𝐽/𝑚𝑜𝑙

= −16.018𝑘𝐽/𝑚𝑜𝑙
Ĥ4= 29.79 + 32.15 -16.018 = 45.922 𝑘𝐽/𝑚𝑜𝑙
51

lOMoARcPSD|8481882
Ethane
Cp = 49.37x10-3 + 13.92x10-5T- 5.816x10-8T + 7.28 x10-12T3 ( J/mol.℃)

449.2
Ĥ5a = ∫25 49.37𝑥10−3 + 13.9210−5 𝑇 − 5.816𝑥10−8 𝑇 2 + 7.28𝑥10−12 𝑇 3 3 𝑑𝑇
= 26.5 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(722.35) ln(101.325/1935) 𝑘𝐽/𝑚𝑜𝑙

= −16.018 𝑘𝐽/𝑚𝑜𝑙
Ĥ5= 26.5 -16.018 = 10.482 𝑘𝐽/𝑚𝑜𝑙
Ethylene
Ĥ6f = 52.28 kJ/mol
Cp = 40.75x10-3 + 11.47x10-5T- 6.891x10-8T + 17.66 x10-12T3 ( J/mol.℃)
449.2
Ĥ6a = ∫25 40.75𝑥10−3 + 11.47 𝑥 10−5 𝑇 − 6.891𝑥10−8 𝑇 2 + 17.66 𝑥10−12 𝑇 3 3 𝑑𝑇
= 21.54 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(722.35) ln(101.325/1935) 𝑘𝐽/𝑚𝑜𝑙

= −16.018𝑘𝐽/𝑚𝑜𝑙
Ĥ6= 52.28 + 26.92 -16.018 = 57.802 𝑘𝐽/𝑚𝑜𝑙
52

lOMoARcPSD|8481882
Toluene
Ĥ7f = 50.0 kJ/mol
Cp = 94.18x10-3 + 38x10-5T- 27.86 x10-8T + 80.33 x10-12T3 ( J/mol.℃)
449.2
Ĥ7a = ∫25 94.18 𝑥10−3 + 38 𝑥 10−5 𝑇 − 27.86𝑥10−8 𝑇 2 + 80.33 𝑥10−12 𝑇 3 3 𝑑𝑇
= 56.076 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(722.35) ln(101.325/1935) 𝑘𝐽/𝑚𝑜𝑙

= −16.018𝑘𝐽/𝑚𝑜𝑙
Ĥ7= 50.0 + 26.92 -16.018 = 90.058 𝑘𝐽/𝑚𝑜𝑙
For outlet stream:

Benzene
Ĥ8f = 82.93 kJ/mol
Cp = 74.06x10-3 + 32.96x10-5T- 25.2x10-8T + 77.57x10-12T3 ( J/mol.℃)
449.2
Ĥ8a = ∫25 4.06𝑥10−3 + 32.96𝑥10−5 𝑇 − 25.2𝑥10−8 − 8𝑇 2 + 77.57𝑥10 − 12𝑇 3 3 𝑑𝑇
= 57.7738 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(722.35) ln(101.325/1920) 𝑘𝐽/𝑚𝑜𝑙

= −17.6681 𝑘𝐽/𝑚𝑜𝑙
Ĥ8= 82.93 + 57.7738 -17.6681= 123.0357 𝑘𝐽/𝑚𝑜𝑙
53

lOMoARcPSD|8481882
Ethylbenzene
Ĥ9f = 29.79 kJ/mol
(25+273.15)+(449.2+273.15)
Tavg = 2
=510.25 𝐾
Cp @ T avg (C8H10) = 209.77 J/mol.℃

449.2
Ĥ9a = ∫25 209.77 𝑑𝑇
= 88.98 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(722.35) ln(101.325/1920) 𝑘𝐽/𝑚𝑜𝑙

= −17.6681 𝑘𝐽/𝑚𝑜𝑙
Ĥ9= 29.79 + 88.98 -17.6681 = 101.106 𝑘𝐽/𝑚𝑜𝑙
1,4-diethylbenzene
Ĥ10f = -20.34 kJ/mol
Ĥ10 ref = −556.52 kJ/kg

= −74.697 𝑘𝐽/𝑚𝑜𝑙
= 90.015 𝑘𝐽/𝑚𝑜𝑙
Ĥ10 = -20.34 + 90.015 - (-74.697) = 144.37 𝑘𝐽/𝑚𝑜𝑙
54

lOMoARcPSD|8481882
Propylene
Ĥ11f = 29.79 kJ/mol
Cp = 159.58x10-3 + 17.71x10-5T- 10.17x10-8T + 24.6x10-12T3 ( J/mol.℃)
449.2
Ĥ11a = ∫25 59.58𝑥10−3 + 17.71𝑥10−5 𝑇 − 10.17𝑥10−8 𝑇 2 + 24.6𝑥10−12 𝑇 3 3 𝑑𝑇
= 40.2644 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(722.35) ln(101.325/1920) 𝑘𝐽/𝑚𝑜𝑙

= −17.6681 𝑘𝐽/𝑚𝑜𝑙
Ĥ11= 29.79 + 40.2644 -−17.6681 = 52.386 𝑘𝐽/𝑚𝑜𝑙
Ethane
Cp = 49.37x10-3 + 13.92x10-5T- 5.816x10-8T + 7.28 x10-12T3 ( J/mol.℃)

449.2
Ĥ12a = ∫25 49.37𝑥10−3 + 13.9210−5 𝑇 − 5.816𝑥10−8 𝑇 2 + 7.28𝑥10−12 𝑇 3 3 𝑑𝑇
= 33.45 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(722.35) ln(101.325/1920) 𝑘𝐽/𝑚𝑜𝑙

= −17.6681 𝑘𝐽/𝑚𝑜𝑙
Ĥ12= 33.45 -16.018 = 15.7826 𝑘𝐽/𝑚𝑜𝑙
55

lOMoARcPSD|8481882
Ethylene
Ĥ13f = 52.28 kJ/mol
Cp = 40.75x10-3 + 11.47x10-5T- 6.891x10-8T + 17.66 x10-12T3 ( J/mol.℃)
449.2
Ĥ13a = ∫25 40.75𝑥10−3 + 11.47 𝑥 10−5 𝑇 − 6.891𝑥10−8 𝑇 2 + 17.66 𝑥10−12 𝑇 3 3 𝑑𝑇
= 26.92 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(722.35) ln(101.325/1920) 𝑘𝐽/𝑚𝑜𝑙

= −17.6681 𝑘𝐽/𝑚𝑜𝑙
Ĥ13= 52.28 + 26.92 -17.6681 = 61.5319 𝑘𝐽/𝑚𝑜𝑙
Toluene
Ĥ14f = 50.0 kJ/mol
Cp = 94.18x10-3 + 38x10-5T- 27.86 x10-8T + 80.33 x10-12T3 (J/mol.℃)
449.2
Ĥ14a = ∫25 94.18 𝑥10−3 + 38 𝑥 10−5 𝑇 − 27.86𝑥10−8 𝑇 2 + 80.33 𝑥10−12 𝑇 3 3 𝑑𝑇
= 56.076 𝑘𝐽/𝑚𝑜𝑙
𝑃1
𝑃2
= (8.3145x10-3)(722.35) ln(101.325/1920) 𝑘𝐽/𝑚𝑜𝑙

= −17.6681 𝑘𝐽/𝑚𝑜𝑙
Ĥ14= 50.0 + 26.92 -16.018 = 90.058 𝑘𝐽/𝑚𝑜𝑙
= [88356.54419 − 63321.34428] 𝑀𝐽/ℎ

= 25035.1999 𝑀𝐽/ℎ
= 6,954.17 kW
56

lOMoARcPSD|8481882
2.3.4 Energy Balance (T-301)

∆H2
T = 81.4℃
P = 1.036 atm
∆H1
T = 73.6°C T-301
P = 1.086 atm
∆H3
T = 145.4℃
P = 1.184 atm
Energy balance:

Inlet Outlet
Substances nin Ĥin nout Ĥout nout Ĥout

(kmol/h) (kJ/mol) (kmol/h) (kJ/mol) (kmol/h) (kJ/mol)
Ethyl benzene 274.62 2.76 271.89

Ĥ1a Ĥ2a Ĥ3a
(C8H10)
Benzene 508.38 507.69 0.51

Ĥ2a Ĥ2b Ĥ3b
(C6H6)
1,4- 31.05 31.05

Diethylbenzene - - - -
(C10H14)
57

lOMoARcPSD|8481882
For inlet stream:

Cp (C8H10) = 8(12) + 10(18) = 276 J/mol.℃ = 0.276kJ/mol.℃
73.6
Ĥ1a = −12.46 + ∫25 0.276 𝑑𝑇
= −12.46 𝑘𝐽/𝑚𝑜𝑙 + 0.276[73.6 − 25] 𝑘 𝐽/𝑚𝑜𝑙

= 0.954 𝑘𝐽/𝑚𝑜𝑙
Cp (C6H6) = 6(12) + 6(18) = 180 J/mol.℃ = 0.18kJ/mol.℃

73.6
Ĥ1b = 48.66 + ∫25 0.18 𝑑𝑇
= 48.66 𝑘𝐽/𝑚𝑜𝑙 + 0.18[73.6 − 25] 𝑘𝐽/𝑚𝑜𝑙

= 57.408𝑘𝐽/𝑚𝑜𝑙
∑ 𝑛𝑖𝑛 Ĥ𝑖𝑛 = (274620 × 0.954) + (508380 × 57.408)
𝑘𝐽 1 ℎ𝑟
= 29447066.52 ×
ℎ𝑟 3600𝑠
= 8179.74 𝑘𝐽/𝑠
For outlet stream:

Cp (C8H10) = 8(12) + 10(18) = 276 J/mol.℃) = 0.276kJ/mol.℃
81.4.0
Ĥ2a = −12.46 + ∫25 276 𝑑𝑇
= −12.46 𝑘𝐽/𝑚𝑜𝑙 + 0.276[81.4 − 25] 𝑘 𝐽/𝑚𝑜𝑙

= 3.106 𝑘𝐽/𝑚𝑜𝑙
Cp (C6H6) = 6(12) + 6(18) = 180 J/mol.℃ = 0.18kJ/mol.℃

139.0
Ĥ2b = 48.66 + ∫25 180 𝑑𝑇
= 48.66 𝑘𝐽/𝑚𝑜𝑙 + 0.18[139 − 25] 𝑘𝐽/𝑚𝑜𝑙

= 58.812 𝑘𝐽/𝑚𝑜𝑙
58

lOMoARcPSD|8481882
Cp (C8H10) = 8(12) + 10(18) = 276 J/mol.℃) = 0.276kJ/mol.℃

145.4
Ĥ3a = −12.46 + ∫25 276 𝑑𝑇
= −12.46 𝑘𝐽/𝑚𝑜𝑙 + 0.276[145.4 − 25] 𝑘 𝐽/𝑚𝑜𝑙

= 20.77𝑘𝐽/𝑚𝑜𝑙
Cp (C6H6) = 6(12) + 6(18) = 180 J/mol.℃ = 0.18kJ/mol.℃

145.4
Ĥ2b = 48.66 + ∫25 180 𝑑𝑇
= 48.66 𝑘𝐽/𝑚𝑜𝑙 + 0.18[145.4 − 25] 𝑘𝐽/𝑚𝑜𝑙

= 70.332 𝑘𝐽/𝑚𝑜𝑙
∑ 𝑛𝑜𝑢𝑡 Ĥ𝑜𝑢𝑡 = (2760 × 3.106 ) + (507690 × 58.812) + (271890 × 20.77)

+ (510 × 70.332)
𝑘𝐽 1 ℎ𝑟
= 35549861.46 ×
ℎ𝑟 3600𝑠
= 9874.96 𝑘𝐽/𝑠
= [9874.96 − 8179.74] 𝑘𝐽/𝑠

= 1695.22 𝑘𝑊
59

lOMoARcPSD|8481882
2.3.5 Energy Balance (T-302)

∆H2
T = 139.0℃
P = 1.086 atm
∆H1
T = 145.4°C T-302
P = 1.184 atm
∆H3
T = 191.1℃
P = 1.382 atm
Energy balance:

Inlet Outlet
Substances nin Ĥin nout Ĥout nout Ĥout

(kmol/h) (kJ/mol) (kmol/h) (kJ/mol) (kmol/h) (kJ/mol)
Ethyl benzene
271.89 Ĥ1a 269.16 Ĥ2a 2.73 Ĥ3a
(C8H10)
Benzene
0.51 Ĥ2a 0.51 Ĥ2b - -
(C6H6)
1,4-
Diethylbenzene 31.05 - 0.0003 - 31.05 Ĥ3b
(C10H14)
60

lOMoARcPSD|8481882
For inlet stream:

Cp (C8H10) = 8(12) + 10(18) = 276 J/mol.℃)
145.4
Ĥ1a = −12.46 + ∫25 276 𝑑𝑇
= −12.46 𝑘𝐽/𝑚𝑜𝑙 + [40130.4 − 6900] 𝐽/𝑚𝑜𝑙

= 20.77 𝑘𝐽/𝑚𝑜𝑙
Cp (C6H6) = 6(12) + 6(18) = 180 J/mol.℃

145.4
Ĥ1b = 48.66 + ∫25 180 𝑑𝑇
= 48.66 𝑘𝐽/𝑚𝑜𝑙 + [26172 − 4500] 𝐽/𝑚𝑜𝑙

= 70.332 𝑘𝐽/𝑚𝑜𝑙
∑ 𝑛𝑖𝑛 Ĥ𝑖𝑛 = (271890 × 20.77) + (510 × 70.332)
𝑘𝐽 1 ℎ𝑟
= 5683024.62 ×
ℎ𝑟 3600𝑠
= 1578.618 𝑘𝐽/𝑠
For outlet stream:

Cp (C8H10) = 8(12) + 10(18) = 276 J/mol.℃)
139.0
Ĥ2a = −12.46 + ∫25 276 𝑑𝑇
= −12.46 𝑘𝐽/𝑚𝑜𝑙 + [38362 − 6900] 𝐽/𝑚𝑜𝑙

= 19.004 𝑘𝐽/𝑚𝑜𝑙
Cp (C6H6) = 6(12) + 6(18) = 180 J/mol.℃

139.0
Ĥ2b = 48.66 + ∫25 180 𝑑𝑇
= 48.66 𝑘𝐽/𝑚𝑜𝑙 + [25020 − 4500] 𝐽/𝑚𝑜𝑙

= 69.180 𝑘𝐽/𝑚𝑜𝑙
61

lOMoARcPSD|8481882
Cp (C8H10) = 8(12) + 10(18) = 276 J/mol.℃)

191.1
Ĥ3a = −12.46 + ∫25 276 𝑑𝑇
= −12.46 𝑘𝐽/𝑚𝑜𝑙 + [52743.6 − 6900] 𝐽/𝑚𝑜𝑙

= 33.384 𝑘𝐽/𝑚𝑜𝑙
∑ 𝑛𝑜𝑢𝑡 Ĥ𝑜𝑢𝑡 = (269160 × 19.004) + (510 × 69.180) + (2730 × 33.384)
𝑘𝐽 1 ℎ𝑟
= 5241536.76 ×
ℎ𝑟 3600𝑠
= 1455.982 𝑘𝐽/𝑠
= [1455.982 − 1578.618] 𝑘𝐽/𝑠

= −122.636 𝑘𝐽/𝑠
62

lOMoARcPSD|8481882
2.3.6 Energy Balance (V-302)

15 ∆H2
T = 73.6 ℃
P = 1.09 atm
14 ∆H1
T = 458.1 °C V-302
P = 18.95 atm
16 ∆H3
T = 73.6 ℃
P = 1.09 atm
Energy balance:
Reference state: 𝐶2 𝐻4 (𝑔), 𝐶2 𝐻6 (𝑔), 𝐶3 𝐻6 (𝑔), 𝐶6 𝐻6 (𝑔), 𝐶6 𝐻5 𝐶𝐻2 𝐶𝐻3 (𝑔), 𝐶10 𝐻10 (𝑔), 458.1𝑜 𝐶, 18.95 𝑎𝑡𝑚
Outlet
Inlet
vapour liquid
Substances
Ĥin nout Ĥout nout Ĥout
nin (kmol/h)
(kJ/mol) (kmol/h) (kJ/mol) (kmol/h) (kJ/mol)
Ethylene (C2H4) 1.62 Ĥ1a 1.62 Ĥ2a - -
Ethane (C2H6) 21.00 Ĥ1b 21.00 Ĥ2b - -
Propylene (C3H6) 6.00 Ĥ1c 6.00 Ĥ2c - -
Benzene (C6H6) 533.55 Ĥ1d 25.14 Ĥ2d 274.62 Ĥ3a
63

lOMoARcPSD|8481882
Ethylbenzene Ĥ1e Ĥ2e Ĥ3b

276.75 2.13 508.38
(C6H5CH2CH3)
1,4-diethylbenzene Ĥ1f Ĥ2f Ĥ3c

31.11 0.0390 31.05
(C10H14)
For inlet stream:

Ĥ1a
Ĥ1b
Ĥ1c 0 kJ/mol
Ĥ1d
Ĥ1e
Ĥ1f
∑ 𝑛𝑖𝑛 Ĥ𝑖𝑛 = 0 𝑘𝐽/ℎ𝑟
For outlet stream: 𝑪𝒑 = 𝒂 + 𝒃𝑻 + 𝑪𝑻𝟐 + 𝒅𝑻𝟑 (𝒌𝑱/𝒎𝒐𝒍. 𝑲)
Vapour stream
Cp (C2H4) = 40.75 × 10−3 + 11.47 × 10−5 (𝑇) − 6.891 × 10−8 (𝑇 2 ) + 17.66 × 10−12 (𝑇 3 )
73.6
Ĥ2a = ∫458.1 40.75 × 10−3 + 11.47 × 10−5 (𝑇) − 6.891 × 10−8 (𝑇2 ) + 17.66 × 10−12 (𝑇3 )𝑑𝑇
= 3.30 − 28.69 𝑘𝐽/𝑚𝑜𝑙

𝑘𝐽
= −25.39
𝑚𝑜𝑙
Cp (C2H6) = 49.37 × 10−3 + 13.95 × 10−5 (𝑇) − 5.816 × 10−8 (𝑇 2 ) + 7.280 × 10−12 (𝑇 3 )
73.6
Ĥ2b = ∫458.1 49.37 × 10−3 + 13.95 × 10−5 (𝑇) − 5.816 × 10−8 (𝑇2 ) + 7.280 × 10−12 (𝑇3)𝑑𝑇
= 4.004 − 35.47 𝑘𝐽/𝑚𝑜𝑙

= −31.47 𝑘𝐽/𝑚𝑜𝑙
64

lOMoARcPSD|8481882
Cp (C3H6) = 59.58 × 10−3 + 17.71 × 10−5 (𝑇) − 10.17 × 10−8 (𝑇 2 ) + 24.60 × 10−12 (𝑇 3 )
73.6
Ĥ2c = ∫458.1 59.58 × 10−3 + 17.71 × 10−5 (𝑇) − 10.17 × 10−8 (𝑇2 ) + 24.60 × 10−12 (𝑇3 )
= 4.85 − 42.89 𝑘𝐽/𝑚𝑜𝑙

= −38.04 𝑘𝐽/𝑚𝑜𝑙
Cp (C6H6) = 74.06 × 10−3 + 32.95 × 10−5 (𝑇) − 25.20 × 10−8 (𝑇 2 ) + 77.57 × 10−12 (𝑇 3 )
73.6
Ĥ2d = ∫458.1 74.06 × 10−3 + 32.95 × 10−5 (𝑇) − 25.20 × 10−8 (𝑇2 ) + 77.57 × 10−12 (𝑇3)
= 5.51 − 30.16 𝑘𝐽/𝑚𝑜𝑙

= −24.65 𝑘𝐽/𝑚𝑜𝑙
Cp (C6H5CH2CH3) = −20.507 + 0.5958(𝑇) − 3.085 × 10−4 (𝑇 2 ) + 3.562 × 10−8 (𝑇 3 ) + 1.24 × 10−11 (𝑇 4 )

73.6
Ĥ2e = ∫458.1 −20.507 + 0.5958(𝑇) − 3.085 × 10−4 (𝑇2 ) + 3.562 × 10−8 (𝑇3 ) + 1.24 × 10−11 (𝑇4 )
= 62.13 − 43671.69 𝑘𝐽/𝑚𝑜𝑙

= −43609.56 𝑘𝐽/𝑚𝑜𝑙
Ĥ2f = 0 kJ/mol
Liquid stream
Cp (C6H6) = 126.5 × 10−3 + 23.4 × 10−5 (𝑇)

73.6
Ĥ3a = ∫458.1 126.5 × 10−3 + 23.4 × 10−5 (𝑇)
= 9.94 − 82.50 𝑘𝐽/𝑚𝑜𝑙

= −72.56 𝑘𝐽/𝑚𝑜𝑙
Cp (C6H5CH2CH3) = 102.11 + 0.05596(𝑇) − 1.561 × 10−3 (𝑇 2 ) + 2.015 × 10−6 (𝑇 3 )

73.6
Ĥ3b = ∫458.1 102.11 + 0.05596(𝑇) − 1.561 × 10−3 (𝑇2 ) + 2.015 × 10−6 (𝑇3 )
= 8838.31 − 77662.26 𝑘𝐽/𝑚𝑜𝑙

= −68823.95 𝑘𝐽/𝑚𝑜𝑙
65

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Ĥ3c = 0 kJ/mol
∑ 𝑛𝑜𝑢𝑡 Ĥ𝑜𝑢𝑡 = 0𝑘𝐽/𝑠
∑ 𝑛𝑜𝑢𝑡 Ĥ𝑜𝑢𝑡 = (1.62 × −25.39) + (21 × −31.47) + (6 × −38.04) + (25.14 × −24.65)

+ (2.13 × −43609.56) + (0.0039 × 0) + (274.62 × −72.56)
+ (508.38 × −68823.95) + (31.05 × 0)
𝑘𝐽 1 ℎ𝑟
= −35103084.43 ×
ℎ𝑟 3600𝑠
= −9750.86 𝑘𝐽/𝑠
= [−9750.896 − 0] 𝑘𝐽/𝑠
= −9750.86 𝑘𝑊
Table 2.3: Energy Balance Summary for Major Equipment

EQUIPMENT Q (kW)
T-301 1695.22
T-302 -122.636
V-302 -9750.86
R-301 238.83
R-302 437.49
R-303 6,954.17
66

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CHAPTER 3: PRELIMINARY DESIGN OF EQUIPMENT

In this context, the major equipment that being discussed are three reactors, a separator, and
two distillation columns. The heuristic used to design these equipments are based on from
3.1 REACTOR
There are four reactors involved in the process of manufacturing ethylbenzene. It labelled as
R-301, R-302, R-303 and R-304. But we only discussed about three reactors, which are R-301,
R-302 and R-303.
Table 3.1 : Heuristic used for Reactors
67

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3.1.1 R-301
Figure 3.1.1: Reactor (R-301).
Table 3.1.1: Stream data for R-301
Stream 6 Stream 7
Temperature (oC) 383.3 441.1
Pressure (bar) 19.85 19.70
Mass flow (kg/hr) 56394 56394
Mass flow (kmol/hr) 777.63 701.52
Component flowrate
Ethylene 83.7 2.55

Ethane 6.3 6.3
Propylene 0 5.49
Benzene 679.53 611.73
Toluene 6 6
1,4-DiEthBenzene 0 2.61
68

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C6H6 + C2H4 C6H5C2H5
(Benzene) + (Ethylene) (Ethylbenzene)
Rate Law, -rA = k exp (-E/RT) CACB
Where: k = 1 × 106
E = 22,500 kcal/kmol
Assume the entering reactant is a pure gas thus yA0 =1 and benzene as the limiting reactant.
𝑅𝑒𝑎𝑐𝑡𝑎𝑛𝑡 𝑐𝑜𝑛𝑠𝑢𝑚𝑒𝑑 𝑖𝑛 𝑟𝑒𝑎𝑐𝑡𝑖𝑜𝑛

𝑆𝑖𝑛𝑔𝑙𝑒 𝑝𝑎𝑠𝑠 𝑐𝑜𝑛𝑣𝑒𝑟𝑠𝑖𝑜𝑛, 𝑋 =
𝑅𝑒𝑎𝑐𝑡𝑎𝑛𝑡 𝑓𝑒𝑑 𝑡𝑜 𝑡ℎ𝑒 𝑟𝑒𝑎𝑐𝑡𝑜𝑟
679.53 − 611.73
𝑋=
679.53
𝑋 = 0.1
𝑦𝐴𝑜 𝑃𝑜 (1)(1985)
𝐶𝐴𝑜 = = = 0.364 𝑘𝑚𝑜𝑙/𝑚3
𝑅𝑇𝑜 (8.314)(656)
ɛ = 𝑦𝑎𝑜 𝜕 = (1)(−1) = −1
𝐹𝐴𝑜 = 679.53 𝑘𝑚𝑜𝑙/ℎ𝑟 and 𝐹𝐵𝑜 = 83.7 𝑘𝑚𝑜𝑙/ℎ𝑟
𝐶𝐴𝑜 (1 − 𝑋) 𝐶𝐴𝑜 (𝜃𝐵 − 1)

𝐶𝐴 = , 𝐶𝐵 =
1 + ɛ𝑋 1 + ɛ𝑋
𝐹𝐵𝑜 83.7 𝑘𝑚𝑜𝑙/ℎ𝑟

𝜃𝐵 = = = 0.123
𝐹𝐴𝑜 679.53 𝑘𝑚𝑜𝑙/ℎ𝑟
69

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X CA CB -ra FAo /-ra
0 0.364 0.045 0.000 392.896
0.02 0.364 0.038 0.000 459.658
0.04 0.364 0.032 0.000 558.517
0.06 0.364 0.024 0.000 719.945
0.08 0.364 0.017 0.000 1030.844
0.1 0.364 0.009 0.000 1877.774
A graph of Fao/-ra vs X
2000
1800
1600
1400
1200
FAo/-ra
1000
800
600
400
200
0
0 0.02 0.04 0.06 0.08 0.1 0.12
Conversion, X
𝑑𝑋
𝑉 = 𝐹𝐴𝑜 ∫
−𝑟𝐴
0.08
0.02
∫ 𝑓(𝑥) 𝑑𝑥 = [392.896 + 4(459.658) + 2(558.517) + 4(719.945) + 1030.844]
0 3
= 48.395
0.1
0.02
∫ 𝑓(𝑥) 𝑑𝑥 = [1030.844 + 1877.774]
0.08 2
= 29.086
𝑉 = 48.395 + 29.086 = 77.481 𝑚3
70

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3.1.2 R-302
Figure 3.1.2 : Reactor (R-302).
Stream 8 Stream 9
Temperature (oC) 380 453.4
Component flowrate
Ethylene 100.2 1.86

Ethane 13.65 13.65
Propylene 5.43 6
Benzene 611.73 524.88
Toluene 0.57 0.0078
1,4-DiEthBenzene 2.61 12.87
71

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Where: k = 1 × 106

611.73 − 524.88
𝑋=
611.73
𝑋 = 0.142
𝑦𝐴𝑜 𝑃𝑜 (1)(1960)
𝐶𝐴𝑜 = = = 0.361 𝑘𝑚𝑜𝑙/𝑚3
𝑅𝑇𝑜 (8.314)(653)
ɛ = 𝑦𝑎𝑜 𝜕 = (1)(−1) = −1
𝐶𝐴𝑜 (1 − 𝑋) 𝐶𝐴𝑜 (𝜃𝐵 − 1)

𝐶𝐴 = , 𝐶𝐵 =
1 + ɛ𝑋 1 + ɛ𝑋

𝜃𝐵 = = = 0.1638
72

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X CA CB -rA FAo/-rA
0 0.3610 0.0591 0.000629 270.3683
0.02 0.3610 0.0530 0.000563 301.8123
0.04 0.3610 0.0466 0.000495 343.4158
0.06 0.3610 0.0399 0.000424 401.0516
0.08 0.3610 0.0329 0.000350 486.1984
0.142 0.3610 0.0092 0.000097 1743.0126
A graph of FAo/-ra vs X
2000
1800
1600
1400
1200
FAo/-ra
1000
800
600
400
200
0
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16
Conversion, X
𝑑𝑋
−𝑟𝐴
0.08
0.02
∫ 𝑓(𝑥) 𝑑𝑥 = [270.3683 + 4(301.8123) + 2(343.4158) + 4(401.0516) + 486.1984]
0 3
= 28.366
0.1
0.062
∫ 𝑓(𝑥) 𝑑𝑥 = [486.1984 + 1743.0126]
0.08 2
= 69.106
𝑉 = 28.366 + 69.106 = 97.472 𝑚3
73

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3.1.3 R-303
Figure 3.1.3 : Reactor (R-303).
Stream 11 Stream 12
Temperature (oC) 380 449.2
Component flowrate
Ethylene 99.51 1.62

Ethane 21 21
Propylene 6 6
Benzene 524.88 445.02
Toluene 0.0078 0
1,4-DiEthBenzene 12.87 30.9
74

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Where: k = 1 × 106

524.88 − 445.02
𝑋=
524.88
𝑋 = 0.152
𝑦𝐴𝑜 𝑃𝑜 (1)(1935)
𝐶𝐴𝑜 = = = 0.1782 𝑘𝑚𝑜𝑙/𝑚3
𝑅𝑇𝑜 (8.314)(653)
ɛ = 𝑦𝑎𝑜 𝜕 = (1)(−1) = −1
𝐶𝐴𝑜 (1 − 𝑋) 𝐶𝐴𝑜 (𝜃𝐵 − 1)

𝐶𝐴 = , 𝐶𝐵 =
1 + ɛ𝑋 1 + ɛ𝑋

𝜃𝐵 = = = 0.1896
75

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X CA CB -rA FAo/-rA
0 0.1782 0.0338 0.00018 822.465
0.03 0.1782 0.0293 0.00015 947.751
0.06 0.1782 0.0246 0.00013 1131.041
0.09 0.1782 0.0195 0.00010 1424.747
0.12 0.1782 0.0141 0.00007 1971.646
0.152 0.1782 0.0079 0.00004 3516.929
A graph of FAo/-rA vs X
4000.0
3500.0
3000.0
2500.0
FAo/-rA
2000.0
1500.0
1000.0
500.0
0.0
0 0.02 0.04 0.06 0.08 0.1 0.12 0.14 0.16
Conversion, X
𝑑𝑋
−𝑟𝐴
0.08
0.03
∫ 𝑓(𝑥) 𝑑𝑥 = [822.465 + 4(947.751) + 2(1131.041) + 4(1424.747) + 1971.646]
0 3
= 145.462
0.1
0.032
∫ 𝑓(𝑥) 𝑑𝑥 = [1971.646 + 3516.929]
0.08 2
= 87.817
𝑉 = 145.462 + 87.817 = 233.279 𝑚3
76

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3.2 SEPARATOR
In the process flow diagram, there is a separator designed as V-302.
Table 3.2.1: Heuristic for Process Vessels (Drums)
77

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Table 3.2.2: Heuristic for Vessels (Pressure and Storage)
78

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3.2.1 Separator (V-302) 15
14
V-302
16
Figure 3.2.1: Separator (V-302)
Table 3.2.1: Information about Vapor and Liquid of V-302

Vapor
Component Molar Flow Rate Molecular Weight Mass Flow Rate
(kmol/hr) (kg/kmol) (kg/hr)
Ethylene (C2H4) 1.62 28.05 45.441
Ethane (C2H6) 21.00 30.07 631.47
Propylene (C3H6) 6.00 42.08 252.48
Benzene (C6H6) 25.14 78.11 1963.6854
Ethylbenzene 2.13 106.10 225.993
(C6H5CH2CH3)
1,4-Diethylbenzene 0.039 134.22 5.2364
(C10H14)
Total 55.929 - 3124.304
Liquid
Component Molar Flow Rate Molecular Weight Mass Flow Rate
(kmol/hr) (kg/kmol) (kg/hr)
Ethylene (C2H4) - - -
Ethane (C2H6) - - -
Propylene (C3H6) - - -
Benzene (C6H6) 274.62 78.11 21450.5682
Ethylbenzene 508.38 106.10 53939.1180
(C6H5CH2CH3)
1,4-Diethylbenzene 31.05 134.22 4167.531
(C10H14)
Total 55.929 - 79557.2172
79

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Density:
For vapour phase with varies temperature:
(MW)P
ρv = , P = 110.0 kPa , R = 8.314 , T = 346.75 K
𝑅𝑇
Molecular Weight Density

(kg/kmol) (kg/m3)
Component
Ethylene (C2H4) 28.05 1.0703
Ethane (C2H6) 30.07 11.4488
Propylene (C3H6) 42.08 1.6056
Benzene (C6H6) 78.11 2.9804

(C6H5CH2CH3)
1,4-Diethylbenzene 134.22 5.1214
(C10H14)
Total - 26.2749
For vapour phase with varies temperature:

ρ1 ρ2
(𝑇𝑐 −𝑇1 )0.3
= (𝑇 0.3 , T2 = 346.75K
𝑐 −𝑇2 )
Pure density T1 Tc Density

(K) (K) (kg/m3)
Component (kg/m3)
Benzene (C6H6) 879.0 293.15 562.2 822.3239
Ethylbenzene 867.0 293.15 617.2 821.2239

(C6H5CH2CH3)
1,4- 862.0 293.15 567.89 807.6643
Diethylbenzene
(C10H14)
Total - - - 2451.2121
80

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Heuristic:
Rule 3: Vertical Vessel
ρ
Rule 9: Gas Velocity u is given by u = k√ρL − 1
v
Assume process is without mesh entrainers, k = 0.0305
ρv = 26.2749 kg/m3
ρL = 2451.2121 kg/m3
ρ
u = 0.0305√ρL − 1
v
2451.2121
u = 0.0305√ −1
26.2749
u = 0.2930 m/s
Rule 12: Good performance obtained at 30%-100% of u at Rule 9; typical value is 75%
uactual= 0.75 (u)
uactual= 0.75 (0.2930 m/s)
uactual= 0.2198 m/s
Convert unit of mass flow rate from kg/hr to kg/s:
𝑘𝑔 1 ℎ𝑟
ṁv = 3124.304 ℎ𝑟 × 3600 𝑠
𝑘𝑔
ṁv = 0.8679 𝑠
𝑘𝑔 1 ℎ𝑟
ṁL = 79557.2172 ℎ𝑟 × 3600 𝑠
𝑘𝑔
ṁL = 22.0992 𝑠
81

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Calculate value of diameter:
ṁv = (ρv)(Ac)(uactual)
D2
0.8679 = (26.2749) ( π × )(0.2198)
4
D = 0.4374 m
Calculate Mass of liquid:
Rule 5: Liquid holdup time is 5 mins based on ½ volume of vessel
Time, t = 5 mins
t = 300 s
mL = ṁL × t
𝑘𝑔
mL = 22.0992 × 300𝑠
𝑠
mL = 6629.76 kg
Calculate Volume of liquid:
ρL = 2451.2121kg/m3
mL = 6629.76 kg
mL
VL = ρL
6629.76 𝑘𝑔
VL = 𝑘𝑔
2451.2121 3
𝑚
VL = 2.7047 m3
82

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Calculate Length, L:
1
VL = 2 𝑉𝑣
1 𝐷2
VL = 2 × 𝜋 × ×𝐿
4
1 (0.4374)2
2.7047 = 2 × 𝜋 × ×𝐿
4
L = 36.00 m
Rule 4: L/D between 2.5 and 5 with optimum at 3.0
𝐿 36.00 𝑚
=
𝐷 0.4374 𝑚
𝐿
= 82.30
𝐷
83

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3.3 DISTILLATION COLUMN
There are two distillation columns in the process flow diagram. The discussed equipment will
be about designing distillation column unit T-301 and T-302.
Table 3.3.1: Heuristic for Towers (Distillation and Gas Absorption)
84

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Table 3.3.2: Heuristic for Towers (Distillation and Gas Absorption)
85

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3.3.1 T-301
Rule 2 (Table 3.3.1)
P1 sat
Relative volatility: α12 = ⁄ sat
P2
Average relative volatility: αave = √(αovhd,12)( αbot,12)
B
Antoine Equation: ln P1 sat (bar) = A −
T(K)+C
Component Parameter for Antoine Equation
Name Formula A B C
Benzene (C6H6) 13.7819 2726.81 -55.578
1,4-diethylbenzene (C10H14) 4.12544 1589.273 -71.131
Vapor pressure, 𝑃1 𝑠𝑎𝑡 of Benzene at 354.55 K:
2726.81
ln P1 sat = 13.7819 −
354.55 + (−55.578)
P1 sat = 1.0577 bar
Vapor pressure, 𝑃2 𝑠𝑎𝑡 of 1,4-diethylbenzene at 418.55 K:
1589.273
ln P2 sat = 4.12544 −
418.55 + (−71.131)
P2 sat = 0.6382 bar
Relative volatility, 𝛼𝑜𝑣ℎ𝑑 :
αovhd = 1.0577 bar⁄0.6382 bar
αovhd = 1.6573
86

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Vapor pressure, 𝑃1 𝑠𝑎𝑡 of Benzene at 418.55 K:
2726.81
ln P1 sat = 13.7819 −
418.55 + (−55.578)
P1 sat = 5.282 bar
Vapor pressure, P2 sat of 1,4-diethylbenzene at 418.55 K:
1589.273
ln P2 sat = 4.12544 −
418.55 + (−71.131)
P2 sat = 0.6382 bar
Relative volatility, αbot :
αbot = 5.282 bar⁄0.6382 bar
αbot = 8.27617
Average relative volatility:
αave = √(αovhd)( αbot)
αave = √(3.74)(3.00)
αave = 3.7035
Table 3.3.1: Stream data for T-301
Stream Number 16 17 18
Mole Flow (kmol/h) 229.2496 143.8197 85.4299
Vapor Phase 0.00 0.00 0.00
Flowrates (kmol/h)
Ethylbenzene 77.3259 0.7766 38.0761
Benzene 143.1435 142.9999 0.1538
1,4-diethylbenzene 8.7803 0.0000 47.2000
87

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Minimum number of trays using Fenske-Underwood equation:

(x⁄1 − x)ovhd
ln [ ]
(x⁄1 − x)bot
Nmin =
ln αave
(0.9943⁄1 − 0.9943)
ln [ ]
(0.0018⁄1 − 0.0018)
Nmin =
ln 3.7035
Nmin = 8.7680
Economical optimum number of theoretical trays is near twice the minimum value 𝑁𝑚𝑖𝑛 :
Ntheo = 2Nmin
Ntheo = 2(8.7680)
Ntheo = 17.536 trays
Safety factor of 10% of the number of trays:

Ntheo (1 + 0.1)
Nact =
𝜀𝑡𝑟𝑎𝑦
17.536(1 + 0.1)
Nact =
0.45
Nact = 43 trays
Minimum reflux when feed is at bubble point:

𝐹
𝑅𝑚𝑖𝑛 =
(𝛼 − 1)𝐷
229.2496
𝑅𝑚𝑖𝑛 =
(3.7035 − 1)(143.8197)
𝑅𝑚𝑖𝑛 = 0.59
88

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Economical optimum reflux ratio is in the range 1.2 – 1.5 times the reflux ratio, 𝑅𝑚𝑖𝑛 :
𝑅 = (1.2 − 1.5)𝑅𝑚𝑖𝑛
𝑅 = (1.2)𝑅𝑚𝑖𝑛 𝑅 = (1.5)𝑅𝑚𝑖𝑛
𝑅 = (1.2)(0.59) - 𝑅 = (1.5)(0.59)
𝑅 = 0.708 𝑅 = 0.885
𝑚 𝑘𝑔 0.5
Peak efficiency of trays with vapor factor in range 1.2 − 1.5 [ ] :
𝑠 𝑚3
𝐹𝑠 = 𝑢𝜌𝑣 0.5
Molar Molecular Mass Mass Density,

Substances,
flowrate weight flowrate fraction, ρ
i (kmol/hr) (kg/kmol) (kg/hr) x (kg/m3)
Ethylbenzene 0.7766 106.16 28574.03 0.0057 3.7815
Benzene 142.9999 78.11 42.18 0.9943 2.7823
Density of components at vapor state in distillate, 𝜌𝑣 :
ρv = ∑ xi ρi
ρv = 0.0057(3.7815) + 0.9943(2.7823)
ρv = 2.7880 kg/m3
Calculating velocity, u
Fs
u=
ρv 0.5
1.2 1.5
u= u=
(2.7880)0.5 (2.7880)0.5
u = 0.7187 m/s - u = 0.898 m/s
From stream 17, the vapor flowrate, 𝜐:

11,252.166 𝑘𝑔 𝑚3 ℎ𝑟
𝜐= × 2.7880 ×
ℎ𝑟 kg 3600 s
𝜐 = 1.1211 𝑚3 /𝑠
89

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Diameter tower, 𝐷𝑡𝑜𝑤𝑒𝑟 :

𝐷𝑡𝑜𝑤𝑒𝑟 = [4𝜐⁄𝜋𝑢 ]0.5
𝐷𝑡𝑜𝑤𝑒𝑟 = [4(1.1211)⁄𝜋(0.7187)]0.5 𝐷𝑡𝑜𝑤𝑒𝑟 = [4(1.1211)⁄𝜋(0.898)]0.5
𝐷𝑡𝑜𝑤𝑒𝑟 = 1.41 𝑚 - 𝐷𝑡𝑜𝑤𝑒𝑟 = 1.26 𝑚
For reasons of accessibility, tray spacing are made 0.5 – 0.6 m

Tower height, 𝐻𝑡𝑜𝑤𝑒𝑟 :
𝐻𝑡𝑜𝑤𝑒𝑟 = 𝑡𝑟𝑎𝑦 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 × 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑡𝑟𝑎𝑦𝑠 + (1.2 𝑚 + 1.8 𝑚)
*Assume tray spacing = 0.5 m
𝐻𝑡𝑜𝑤𝑒𝑟 = 0.5 × 43 + 3𝑚
𝐻𝑡𝑜𝑤𝑒𝑟 = 24.5 𝑚
Limit tower height to about 53 m max. L/D be less than 30

𝐿 24.5
𝐷
= = 17.376
1.41
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3.3.2 T-302
P1 sat
Relative volatility: α12 = ⁄ sat
P2
Average relative volatility: αave = √(αovhd,12)( αbot,12)
B
Antoine Equation: ln P1 sat (bar) = A −
T(K)+C
Component Parameter for Antoine Equation
Name Formula A B C
Ethylbenzene (C6H5CH2CH3) 4.07488 1419.315 -60.539
1,4- (C10H14) 4.12544 1589.273 -71.131

diethylbenzene
Vapor pressure, 𝑃1 𝑠𝑎𝑡 of Ethylbenzene at 412.15 K:
1419.315
ln P1 sat = 4.07488 −
412.15 + (−60.539)
P1 sat = 1.0921 bar
Vapor pressure, 𝑃2 𝑠𝑎𝑡 of 1,4-diethylbenzene at 412.15 K:
1589.273
ln P2 sat = 4.12544 −
412.15 + (−71.131)
P2 sat = 0.2918 bar
Relative volatility, 𝛼𝑜𝑣ℎ𝑑 :
αovhd = 1.0921 bar⁄0.2918 bar
αovhd = 3.74
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Vapor pressure, P1 sat of Ethylbenzene at 464.25 K:
1419.315
ln P1 sat = 4.07488 −
464.25 + (−60.539)
P1 sat = 3.6242 bar
Vapor pressure, P2 sat of 1,4-diethylbenzene at 363 K:
1589.273
ln P2 sat = 4.12544 −
464.25 + (−71.131)
P2 sat = 1.2098 bar
Relative volatility, αbot :
αbot = 3.6242 bar⁄1.2098 bar
αbot = 3.00
Average relative volatility:
αave = √(αovhd)( αbot)
αave = √(3.74)(3.00)
αave = 3.35
Table 3.3.1: Stream data for T-301

Stream Number 18 19 20
Mole Flow (kmol/h) 303.45 269.6703 33.78
Vapor Phase 0.00 0.00 0.00
Flowrates (kmol/h)
Ethylbenzene 271.89 269.16 2.73
Benzene 0.51 0.51 0.0
1,4-diethylbenzene 31.05 0.0003 31.05
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Minimum number of trays using Fenske-Underwood equation:

(x⁄1 − x)ovhd
ln [ ]
(x⁄1 − x)bot
Nmin =
ln αave
(0.9981⁄1 − 0.9981)
ln [ ]
(0.0808⁄1 − 0.0808)
Nmin =
ln 3.35
Nmin = 7.19
Economical optimum number of theoretical trays is near twice the minimum value 𝑁𝑚𝑖𝑛 :
Ntheo = 2Nmin
Ntheo = 2(7.19)
Ntheo = 14.38 trays
Safety factor of 10% of the number of trays:

Ntheo (1 + 0.1)
Nact =
𝜀𝑡𝑟𝑎𝑦
14.38(1 + 0.1)
Nact =
0.45
Nact = 35 trays
Minimum reflux when feed is at bubble point:

𝐹
𝑅𝑚𝑖𝑛 =
(𝛼 − 1)𝐷
303.45
𝑅𝑚𝑖𝑛 =
(3.35 − 1)(269.6703)
𝑅𝑚𝑖𝑛 = 0.48
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Economical optimum reflux ratio is in the range 1.2 – 1.5 times the reflux ratio, 𝑅𝑚𝑖𝑛 :
𝑅 = (1.2 − 1.5)𝑅𝑚𝑖𝑛
𝑅 = (1.2)𝑅𝑚𝑖𝑛 𝑅 = (1.5)𝑅𝑚𝑖𝑛
𝑅 = (1.2)(0.48) - 𝑅 = (1.5)(0.48)
𝑅 = 0.576 𝑅 = 0.72
𝑚 𝑘𝑔 0.5
Peak efficiency of trays with vapor factor in range 1.2 − 1.5 [ ] :
𝑠 𝑚3
(MW)P
ρv = , P = 110.0 kPa , R = 8.314 , T = 412.15 K
𝑅𝑇
Molecular Weight Density

(kg/kmol) (kg/m3)
Component
Benzene (C6H6) 78.11 2.5075

(C6H5CH2CH3)
1,4-Diethylbenzene 134.22 4.3087
(C10H14)
Total - 10.2222
Calculating velocity, u
Fs
u=
ρv 0.5
1.2 1.5
u= u=
(10.2222)0.5 (10.2222)0.5
u = 0.38 m/s - u = 0.47m/s
From stream 19, the vapor flowrate, 𝜐:

28616.25 𝑘𝑔 𝑚3 ℎ𝑟
𝜐= × 𝟏𝟎.𝟐𝟐𝟐𝟐kg ×
ℎ𝑟 3600 s
𝜐 = 0.7776 𝑚3 /𝑠
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Diameter tower, 𝐷𝑡𝑜𝑤𝑒𝑟 :

𝐷𝑡𝑜𝑤𝑒𝑟 = [4𝜐⁄𝜋𝑢 ]0.5
𝐷𝑡𝑜𝑤𝑒𝑟 = [4(0.7776)⁄𝜋(0.38)]0.5 𝐷𝑡𝑜𝑤𝑒𝑟 = [4(0.7776)⁄𝜋(0.47)]0.5
𝐷𝑡𝑜𝑤𝑒𝑟 = 1.61 𝑚 - 𝐷𝑡𝑜𝑤𝑒𝑟 = 1.45 𝑚
For reasons of accessibility, tray spacing are made 0.5 – 0.6 m

Tower height, 𝐻𝑡𝑜𝑤𝑒𝑟 :
𝐻𝑡𝑜𝑤𝑒𝑟 = 𝑡𝑟𝑎𝑦 𝑠𝑝𝑎𝑐𝑖𝑛𝑔 × 𝑛𝑢𝑚𝑏𝑒𝑟 𝑜𝑓 𝑎𝑐𝑡𝑢𝑎𝑙 𝑡𝑟𝑎𝑦𝑠 + (1.2 𝑚 + 1.8 𝑚)
*Assume tray spacing = 0.5 m
𝐻𝑡𝑜𝑤𝑒𝑟 = 0.5 × 35 + 3𝑚
𝐻𝑡𝑜𝑤𝑒𝑟 = 20.5 𝑚
Limit tower height to about 53 m max. L/D be less than 30

𝐿 20.5
𝐷
= = 12.73
1.61
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CHAPTER 4: COST CALCULATION
4.1 BARE MODULE COST FOR EACH EQUIPMENT
Table 4.1 Summary of Bare Module Cost for Each Equipment at 2019
Equipment FP FM FBM Cp° (2019) CBM (2019) CBM° (2019)

E-301 1.07 2.8 3.24 54,932.31 177,980.68 180,727.30
E-302 1.07 2.8 6.6 64,200.64 423,724.22 211,412.71
E-303 1.0 2.8 6.28 38,4259 2,413,146.52 1,264,212.11
E-304 1.0 1.0 3.29 409,078.84 1,345,869.38 1,345,869.38
E-305 1.0 1.0 3.29 230,045.60 758,034.40 758,034.40
E-306 1.0 1.0 3.29 45,896.84 151,000.60 151,000.60
E-307 1.0 1.0 3.29 50,749.17 166,964.77 166,964.77
E-308 1.0 1.0 3.29 32,667.66 107,476.59 107,476.59
E-309 1.0 1.0 3.29 32,082.48 105,551.36 105,551.36
H-301 1 1.244 2.2 4356181.24 11,921,996.82 9,583,598.73
H-301 1 1.244 2.2 4356181.24 11,921,996.82 9,583,598.73
P-301 A/B 1.17 1.40 4.10 38,964.56 159,754.70 126,245.17
P-302 A/B 1.00 1.60 4.05 8,854.25 35,859.71 28,687.77
P-303 A/B 1.00 1.60 4.05 8,854.25 35,859.71 28,687.77
P-304 A/B 1.00 1.60 3.49 9,543.60 38,368.08 30,694.46
P-305 A/B 1.17 1.40 4.10 16,435.96 67,387.44 53,252.51
R-301 - - 4 2,603.80 10,415.20 2,603.80
R-302 - - 4 2,337.55 9,350.23 2,337.55
R-303 - - 4 1,550.83 6,203.32 1,550.83
R-304 - - 4 9,413.82 37,655.28 9,413.82
V-301 2.92 1.00 5.92 25,723.06 152,280.52 77,426.41
V-302 0.6070 1.0 3.3547 8,524.18 28,596.08 34,693.41
V-302 0.5859 1.0 3.3163 7,880.15 26,132.94 32,072.21
Demister Fp=1 - 1 4,577.99 13,733.97 13,733.97
Pad Fq =
3.00
V-304 0.73 1.00 2.60 23,881.32 62,091.43 186,895.20
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T-301 1.0 1.0 3.6878 62, 341.04 229901.29 253,728.03

(Vessel)
T-301 1.0 1.0 2.0000 2,469.84 121,1639.52 106, 203.12
(Tray)
T-302 1.0 1.0 3.6878 50,412.09 189,156.24 205,177.21
(Vessel)
T-302 1.0 1.0 2.0000 2,327.20 93,291.03 81,452.00
(Tray)
Total ($) 5,884,448.23 31,901,418.85 24,627,098.80
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4.1.1 HEAT EXCHANGERS
Table 4.1.1.1: Information on Heat Exchangers
Equipment Capacity/Size Material of Operating

Number Construction Pressure
(barg)
E-301 Area = 187.8m2 Stainless Discharge =
19.6
Reactor Inter- 62.6 m2 (3) Steel
cooler 1-2 exchanger, floating head
E-302 Area = 240.3 m2 Stainless Discharge =
19.35
Reactor Inter- 80.1 m2 (3) Steel
cooler 1-2 exchanger, floating head
E-303 Area = 1638 m2 Stainless Discharge =
1.1
HP Steam Boiler 546 m2 (3) Steel
1-2 exchanger, floating head
E-304 Area = 4701 m2 Carbon Steel Discharge =
LP Steam Boiler 1567 m2 (3) 1.1
Process stream tubes
(Fixed head)
E-305 Area = 1044 m2 Carbon Steel Discharge =
Reactor Effluent 348 m2 (3) 1.1
Cooler Process stream in shell
(Floating head)
E-306 Area = 173.4 m2 Carbon Steel Discharge =
Benzene Reboiler 57.8 m2 (3) 1.2
Process stream in shell
(Fixed head)
Area = 163.8 m2 Carbon Steel Discharge =
E-307 54.6 m2 (3) 1.05
Benzene Process stream in shell
Condenser (Floating Head)
E-308 22.6 m2(3) 1.1
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Ethylbenzene Process stream in shell

Reboiler (Fixed Head)
E-309 17.5 m2(3) 1.1
Ethylbenzene Process stream in shell
Condenser (Floating Head)
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Table 4.1.1.2: Results of Capital Cost Estimate for Heat Exchanger in 2001 (CEPCI,
2001 = 394, 2019 = 619.2)

E-301 1.07 2.8 3.24 34,953.70 230,807.24 113,249.99
E-302 1.07 2.8 6.6 40,851.18 269,755.05 134,400.38
E-303 1.0 2.8 6.28 244,505.92 1,535,008.17 804,424.48
E-304 1.0 1.0 3.29 260,298.90 856,383.30 856,383.30
E-305 1.0 1.0 3.29 146,608.20 482.341.00 482.341.00
E-306 1.0 1.0 3.29 29,204.38 96,082.42 96,082.42
E-307 1.0 1.0 3.29 32,291.31 106,238.42 106,238.42
E-308 1.0 1.0 3.29 20,786.59 68,387.88 68,387.88
E-309 1.0 1.0 3.29 20,414.24 67,162.84 67,162.84
Total($) 829,914.42 3,229,825.32 2,246,329.71
Table 4.1.1.3: Results of Capital Cost Estimate for Heat Exchanger in 2019 (CEPCI,
2001 = 394, 2019 = 619.2)

E-301 1.07 2.8 3.24 54,932.31 177,980.68 180,727.30
E-302 1.07 2.8 6.6 64,200.64 423,724.22 211,412.71
E-303 1.0 2.8 6.28 38,4259 2,413,146.52 1,264,212.11
E-304 1.0 1.0 3.29 409,078.84 1,345,869.38 1,345,869.38
E-305 1.0 1.0 3.29 230,045.60 758,034.40 758,034.40
E-306 1.0 1.0 3.29 45,896.84 151,000.60 151,000.60
E-307 1.0 1.0 3.29 50,749.17 166,964.77 166,964.77
E-308 1.0 1.0 3.29 32,667.66 107,476.59 107,476.59
E-309 1.0 1.0 3.29 32,082.48 105,551.36 105,551.36
Total ($) 1,303,912.54 5,649,748.52 4,291,249.22
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COSTING CALCULATION FOR HEAT EXCHANGERS
E-301
From Table A.1, K1=4.8306, K2= -0.8509, K3=0.3187
𝐿𝑜𝑔 𝐶𝑃 ° = 𝐾1 + 𝐾2 𝑙𝑜𝑔10 (𝐴, 𝑚2 ) + 𝐾3 [𝑙𝑜𝑔10 (𝐴, 𝑚2 )]2

𝐿𝑜𝑔 𝐶𝑃 ° = 4.8306 + −0.8509 log(187.8) + 0.3187 [log(187.8)]2
CP°,2001 = 34953.70
From Table A.2, C1= 0.03881, C2= -0.11272, C3= 0.08183

𝐿𝑜𝑔 𝐹𝑃 = 𝐶1 + 𝐶2 𝑙𝑜𝑔10 𝑃 + 𝐶3 (𝑙𝑜𝑔10 𝑃)2
𝐿𝑜𝑔 𝐹𝑃 = 0.03881 + −0.11272 log(19.6) +0.08183 [log(19.6)]2
𝐹𝑃 = 1.07
From Figure A.18 FM=2.8 (Identification Number = 5 from Table A.3)

From Table A.4, B1=1.63 and B2=1.66
CBM,2001 = CP° [B1+ B2 (𝐹𝑀 ) (𝐹𝑃 )]
CBM,2001 = 34953.70 [1.63+1.66(2.8) (1.07)] = $230807.24
When 𝐹𝑃 = 1 and FM=1.0

CBM°,2001 = 34953.70 [1.89+1.35(1.0) (1.0)] = $113249.99
From Table A.5,

𝐶𝐵𝑀
FBM =
𝐶𝑃 °
113249.99
FBM = = 3.24
34953.70
For 2019, CP°,2019 = 34953.70 (619.2/394) = 54932.31

CBM,2019 = CP°2019FBM = 54932.31 (3.24) = $177980.68
CBM°,2019 = 54932.31 [1.63+1.66(1.0) (1.0)] = $180727.30
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E-302
From Table A.1, K1=4.8306, K2= -0.8509, K3=0.3187

𝐿𝑜𝑔 𝐶𝑃 ° = 4.8306 + −0.8509 log(240.3) + 0.3187 [log(240.3)]2
CP°,2001 = 40851.18
From Table A.2, C1= 0.03881, C2= -0.11272, C3= 0.08183

𝐿𝑜𝑔 𝐹𝑃 = 0.03881 + −0.11272 log(19.35) +0.08183 [log(19.35)]2
𝐹𝑃 = 1.07

CBM,2001 = CP° [B1+ B2 (𝐹𝑀 ) (𝐹𝑃 )]
CBM,2001 = 40851.18 [1.63+1.66(2.8) (1.07)] = $269755.05

CBM°,2001 = 40851.18 [1.63+1.66(1.0) (1.0)] = $134400.38
From Table A.5,

𝐶𝐵𝑀
FBM =
𝐶𝑃 °
269755.05
FBM = = 6.6
40851.18
For 2019, CP°,2019 = 40851.18 (619.2/394) = 64200.64

CBM,2019 = CP°2019FBM = 64200.64 (6.6) = $423724.22
CBM°,2019 = 64200.64 [1.63+1.66(1.0) (1.0)] = $211412.71
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E-303
From Table A.1, K1=4.8306, K2= -0.8509, K3=0.3187

𝐿𝑜𝑔 𝐶𝑃 ° = 4.8306 + −0.8509 log(1638) + 0.3187 [log(1638)]2
CP°,2001 = 244505.92
From Table A.2, C1= 0, C2= 0, C3= 0

𝐿𝑜𝑔 𝐹𝑃 = 0
𝐹𝑃 = 1

CBM,2001 = CP° [B1+ B2 (𝐹𝑀 ) (𝐹𝑃 )]
CBM,2001 = 244505.92[1.63+1.66(2.8) (1)] = $1535008.17

CBM°,2001 = 244505.92 [1.63+1.66(1.0) (1.0)] = $804424.48
From Table A.5,

𝐶𝐵𝑀
FBM =
𝐶𝑃 °
1535008.17
FBM = = 6.28
244505.92
For 2019, CP°,2019 = 244505.92 (619.2/394) = 384259

CBM,2019 = CP°2019FBM = 384259 (6.28) = $2413146.52
CBM°,2019 = 384259 [1.63+1.66(1.0) (1.0)] = $1264212.11
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E-304
From Table A.1, K1 = 4.3247, K2 = -0.303, K3 = 0.1634
Log10 Cp° = K1 + K2 log10 (Area, m2) + K3 [log10 (Area, m2)] 2
Log10 Cp° = 4.3247 – 0.3030 log10 (4701) + 0.1634 [log10 (4701)] 2
Cp°2001 = $260298.87
From Table A.2, C1 = C2 = C3 = 0
Log10 FP = C1 + C2 log10 P + C3 [log10 P] 2
FP = 1
From Figure A.18, FM = 1 (Identification Number = 1 from Table A.3)
FBM = [B1 + B2 FM FP] = 1.63+1.66(1)(1)
= 3.29
From Table A.4, B1 = 1.63 and B2 = 1.66
CBM = Cp° [B1 + B2 FM FP]
CBM = 260298.87[1.63+1.66(1)(1)]
CBM = $856383.30
*CBM° = CBM because of FP and FM are equal to 1.0
For 2019,
Cp°, 2019 = 260298.87 (619.2/394) = $409078.84
CBM, 2019 = Cp°, 2019 FBM = 409078.84(3.29) = $1345869.38
CBM, 2019 = CBM°, 2019 = $1345869.38
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E-305
From Table A.1, K1 = 4.3247, K2 = -0.303, K3 = 0.1634
Log10 Cp° = 4.8306 – 0.8509 log10 (1044) + 0.3187 [log10 (1044)] 2
Cp°2001 = $146608.20
Log10 FP = C1 + C2 log10 P + C3 [log10 P]2
FP = 1
FBM = [B1 + B2 FM FP] = 1.63+1.66(1)(1)
= 3.29
CBM = 146608.20[1.63+1.66(1)(1)]
CBM = $482341.01
For 2019,
Cp°, 2019 = 146608.20 (619.2/394) = $230405.59
CBM, 2019 = Cp°, 2019 FBM = 230405.59(3.29) = $758034.40
CBM, 2019 = CBM°, 2019 = $758034.40
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E-306
From Table A.1, K1 = 4.3247, K2 = -0.303, K3 = 0.1634
Log10 Cp° = 4.3247 – 0.3030 log10 (173.4) + 0.1634 [log10 (173.4)] 2
Cp°2001 = $29204.38
FP = 1
FBM = [B1 + B2 FM FP] = 1.63+1.66(1)(1)
= 3.29
CBM = 29204.38[1.63+1.66(1)(1)]
CBM = $96082.42
For 2019,
Cp°, 2019 = 29204.38 (619.2/394) = $45896.84
CBM, 2019 = Cp°, 2019 FBM = 45896.84(3.29) = $151000.60
CBM, 2019 = CBM°, 2019 = $151000.60
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E-307
From Table A.1, K1 = 4.8306, K2 = -0.8509, K3 = 0.3187
Log10 Cp° = 4.8306 – 0.8509 log10 (163.8) + 0.3187[log10 (163.8)] 2
Cp°2001 = $32,291.31
FP = 1
FBM = [B1 + B2 FM FP] = 1.63+1.66(1)(1)
= 3.29
CBM ,2001 = Cp° [B1 + B2 FM FP]
CBM ,2001 = $32,291.31 [1.63+1.66(1)(1)]
CBM ,2001 = $106,238.42

𝐼
For 2019, 𝐶2019 = 𝐶2001 ( 𝐼2019 )
2001
619.2
Cp°, 2019 = $32,291.31 ( ) = $50,749.17
394
CBM, 2019 = Cp°, 2019 FBM = $50,749.17(3.29) = $166,964.77
CBM, 2019 = CBM°, 2019 = $166,964.77
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E-308
From Table A.1, K1 = 4.3247, K2 = -0.303, K3 = 0.1634
Log10 Cp° = 4.8306 – 0.8509 log10 (67.8) + 0.3187 [log10 (67.8)] 2
Cp°2001 = $20,786.59
Log10 FP = C1 + C2 log10 P + C3 [log10 P]2
FP = 1
FBM = [B1 + B2 FM FP] = 1.63+1.66(1)(1)
= 3.29
CBM ,2001 = Cp° [B1 + B2 FM FP]
CBM ,2001 = $20,786.59 [1.63+1.66(1)(1)]
CBM ,2001 = $68,387.88

𝐼
For 2019, 𝐶2019 = 𝐶2001 ( 𝐼2019 )
2001
619.2
Cp°, 2019 = $20,786.59 ( ) = $32,667.66
394
CBM, 2019 = Cp°, 2019 FBM = $32,667.66(3.29) = $107,476.59
CBM, 2019 = CBM°, 2019 = $107,476.59
108

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E-309
From Table A.1, K1 = 4.8306, K2 = -0.8509, K3 = 0.3187
Log10 Cp° = 4.3247 – 0.3030 log10 (52.5) + 0.1634 [log10 (52.5)] 2
Cp°2001 = $20,414.24
FP = 1
FBM = [B1 + B2 FM FP] = 1.63+1.66(1)(1)
= 3.29
CBM ,2001 = Cp° [B1 + B2 FM FP]
CBM ,2001 = $20,414.24[1.63+1.66(1)(1)]
CBM ,2001 = $67,162.84

𝐼
For 2019, 𝐶2019 = 𝐶2001 ( 𝐼2019 )
2001
619.2
Cp°, 2019 = $ 20,414.24( ) = $32,082.48
394
CBM, 2019 = Cp°, 2019 FBM = $32,082.48(3.29) = $105,551.36
CBM, 2019 = CBM°, 2019 = $105,551.36
109

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4.1.2 HEATER
COSTING CALCULATION OF FIRED HEATER
H-301 (Non Reactive Fired heater)
Q = 67128
Tubes = Stainless steel
Efficiency = 75%
From Table A.1, K1 = 7.3488, K2 = -1.1666, K3 = 0.2028
Log10 Cp° = K1 + K2 log10 (capacity, kW) + K3 [log10 (kW)] 2
Log10 Cp° = 7.3488-1.1666log10 (67128) + 0.2028[log10 (67128)] 2
Cp°2001 = $2771859.51
FP = 1
⩟T= 324.8°C
Ft=1+0.00184⩟T – 0.000000355(⩟T)2
Ft= 1.244
From table A.19, identification number = 56
FBM = 2.2
CBM ,2001 = Cp° FBM Fp FT
CBM ,2001 = ($2771859.51)(2.2)(1.0)(1.244)`
CBM ,2001 = $7,586,025.11

From table A.19, identification number = 56(CS-Fired heater), FBM°=11.45
*CBM° = Cp° FBM° Fp FT
110

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= ($2,771,859.51)(2.2)(1.0)(1.0)
=$6,098,090.92
𝐼
For 2019, 𝐶2019 = 𝐶2001 ( 𝐼2019 )
2001
619.2
Cp°, 2019 = $2771859.51 ( ) = $4356181.24
394
CBM, 2019 = Cp°, 2019 FBM Fp FT= $4356181.24 (2.2)(1.0)(1.244) = $11,921,996.82
CBM, 2019° = Cp°, 2019 FBM° Fp FT = $9,583,598.73
111

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4.1.3 PUMP
Table 4.1.3.1: Information on Pumps

(barg)
P-301 A/B Powershaft = 45 kW Carbon Steel Discharge =
Benzene Feed 15 kW (3) 19.85
Pumps Positive displacement/Electric drive
Benzene Reflux 1 kW (3) 1.05
Pumps Centrifugal/Electric drive
EB Reflux Pumps 1 kW (3) 1.10
Centrifugal/Electric drive
P-304 A/B Powershaft = 4.2 kW Carbon Steel Discharge =
DEB Recycle 1.4 kW (3) 20.00
Pumps Centrifugal/Electric drive
P-305 A/B Powershaft = 8.1 kW Carbon Steel Discharge =
Benzene Recycle 2.7 kW (3) 20.00
Pumps Positive displacement/Electric drive
Table 4.1.3.2: Results of Capital Cost Estimate for Pumps in 2001 (CEPCI, 2001 = 394,
2019 = 619.2)

P-301 A/B 1.17 1.40 4.10 24,793.34 101,684.92 80,330.42
P-302 A/B 1.00 1.60 4.05 5,634.00 22,817.70 18,254.16
P-303 A/B 1.00 1.60 4.05 5,634.00 22,817.70 18,254.16
P-304 A/B 1.00 1.60 3.49 6,072.64 21,193.52 19,531.04
P-305 A/B 1.17 1.40 4.10 10,458.28 42,892.54 33,884.82
Total($): 52,592.26 211,406.38 170,254.60
112

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Table 4.1.3.3: Results of Capital Cost Estimate for Pumps in 2019 (CEPCI, 2001 = 394,
2019 = 619.2)

P-301 A/B 1.17 1.40 4.10 38,964.56 159,754.70 126,245.17
P-302 A/B 1.00 1.60 4.05 8,854.25 35,859.71 28,687.77
P-303 A/B 1.00 1.60 4.05 8,854.25 35,859.71 28,687.77
P-304 A/B 1.00 1.60 3.49 9,543.60 38,368.08 30,694.46
P-305 A/B 1.17 1.40 4.10 16,435.96 67,387.44 53,252.51
Total($): 82,652.62 337,229.64 267,567.68
113

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COSTING CALCULATIONS FOR PUMPS

P-301 A/B Benzene Feed Pumps
From Table A.1, K1=3.4771, K2=0.1350, K3=0.1438
𝐿𝑜𝑔 𝐶𝑃 ° = 𝐾1 + 𝐾2 𝑙𝑜𝑔10 (𝑃𝑜𝑤𝑒𝑟, 𝑘𝑊) + 𝐾3 [𝑙𝑜𝑔10 (𝑃𝑜𝑤𝑒𝑟, 𝑘𝑊)]2
𝐿𝑜𝑔 𝐶𝑃 ° = 3.4771 + 0.1350 log(45) + 0.1438 log(45)2
CP°,2001 = 12396.67
CP°,2001 = 2 (12396.67) = 24793.34
From Table A.2, C1= -0.245382, C2= 0.259016, C3= -0.01363

𝐿𝑜𝑔 𝐹𝑃 = −0.245382 + 0.259016 log(19.85) +-0.01363 log(19.85)2
𝐹𝑃 = 1.17
From Figure A.18, FM=1.4 (Identification Number = 32 from Table A.3)

CBM,2001 = CP° [B1+ B2 (𝐹𝑀 ) (𝐹𝑃 )]
CBM,2001 = 12396.67 [1.89+1.35(1.4) (1.17)] = $50842.46
CBM,2001 = 2(50842.46) = $101684.92

CBM°,2001 = 12396.67 [1.89+1.35(1.0) (1.0)] = $40165.21
CBM°,2001 = 2(40165.21) = $80330.42
From Table A.5,

𝐶𝐵𝑀
FBM =
𝐶𝑃 °
50842.46
FBM = = 4.10
12396.67
For 2019, CP°,2019 = 24793.34 (619.2/394) = 38964.56

CBM,2019 = CP°2019FBM = 38964.56 (4.10) = $159754.70
CBM°,2019 = 38964.56 [1.89+1.35(1.0) (1.0)] = $126245.17
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P-302 A/B Benzene Reflux Pumps

From Table A.1, K1=3.3892, K2=0.0536, K3=0.1538
𝐿𝑜𝑔 𝐶𝑃 ° = 3.3892 + 0.0536 log(3) + 0.1538 log(3)2
CP° = 2817
CP° = 2 (2817) = 5634
From Table A.2, C1=0, C2=0, C3=0

𝐿𝑜𝑔 𝐹𝑃 = 0 + 0 log(1.05) + 0 log(1.05)2
𝐹𝑃 = 1

CBM = CP° [B1+ B2 (𝐹𝑀 ) (𝐹𝑃 )]
CBM = 2817 [1.89+1.35(1.6) (1.0)] = $11408.85
CBM = 2(11408.85) = $22817.7
When 𝐹𝑃 = 1 and FM = 1.0

CBM°= 2817 [1.89+1.35(1.0) (1.0)] = $9127.08
CBM°= 2(9127.08) = $18254.16
From Table A.5,

𝐶𝐵𝑀
FBM =
𝐶𝑃 °
11408.85
FBM = = 4.05
2817
For 2019,
CP°,2019 = 5634 (619.2/394) = 8854.25
CBM,2019 = CP°2019FBM = 8854.25 (4.05) = $35859.71
CBM°,2019 = 8854.25 [1.89+1.35(1.0) (1.0)] = $28687.77
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P-303 A/B EB Reflux Pumps

From Table A.1, K1=3.3892, K2=0.0536, K3=0.1538
𝐿𝑜𝑔 𝐶𝑃 ° = 3.3892 + 0.0536 log( 3) + 0.1538 log( 3)2
CP° = 2817
CP° = 2 (2817) = 5634

𝐿𝑜𝑔 𝐹𝑃 = 0 + 0 log(1.10) + 0 log(1.10)2
𝐹𝑃 = 1

CBM = CP° [B1+ B2 (𝐹𝑀 ) (𝐹𝑃 )]
CBM = 2817[1.89+1.35(1.6) (1.0)] = $11408.85
CBM = 2(11408.85) = $22817.7

CBM°= 2817 [1.89+1.35(1.0) (1.0)] = 9127.08
CBM°= 2(9127.08) = 18254.16
From Table A.5,

𝐶𝐵𝑀
FBM =
𝐶𝑃 °
11408.85
FBM = = 4.05
2817
For 2019,
CP°,2019 = 5634 (619.2/394) = 8854.25
CBM,2019 = CP°2019FBM = 8854.25(4.05) = 35859.71
CBM°,2019 = 8854.25[1.89+1.35(1.0) (1.0)] = $28687.77
116

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P-304 A/B DEB Recycle Pumps

From Table A.1, K1=3.3892, K2=0.0536, K3=0.1538
𝐿𝑜𝑔 𝐶𝑃 ° = 3.3892 + 0.0536 log(4.2) + 0.1538 log(4.2)2
CP° = 3036.32
CP° = 2 (3036.32) = 6072.64

𝐿𝑜𝑔 𝐹𝑃 = 0 + 0 log(20.00) + 0 log(20.00)2
𝐹𝑃 = 1

CBM = CP° [B1+ B2 (𝐹𝑀 ) (𝐹𝑃 )]
CBM = 3036.32 [1.89+1.35(1.6) (1.0)] = $10596.76
CBM = 2(10596.76) = $21193.52

CBM°= 3036.32 [1.89+1.35(1.0) (1.0)] = 9765.52
CBM°= 2(9765.52) = 19531.04
From Table A.5,

𝐶𝐵𝑀
FBM =
𝐶𝑃 °
10596.76
FBM = = 3.49
3036.32
For 2019,
CP°,2019 = 6072.64 (619.2/394) = 9543.60
CBM,2019 = CP°2019FBM = 9473.60(3.49) = 38368.08
CBM°,2019 = 9473.60 [1.89+1.35(1.0) (1.0)] = 30694.46
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P-305 A/B Benzene Recycle Pumps

From Table A.1, K1=3.4771, K2=0.1350, K3=0.1438
𝐿𝑜𝑔 𝐶𝑃 ° = 3.4771 + 0.1350 log(8.1 ) + 0.1438 log(8.1 )2
CP° = 5229.14
CP° = 2 (5229.14) = $10458.28
From Table A.2, C1= -0.245382, C2= 0.259016, C3= -0.01363

𝐿𝑜𝑔 𝐹𝑃 = −0.245382 + 0.259016 log(20.00) + (-0.01363)log(20.00)2
𝐹𝑃 = 1.17

CBM = CP° [B1+ B2 (𝐹𝑀 ) (𝐹𝑃 )]
CBM = 5229.14 [1.89+1.35(1.4) (1.17)] = $21446.27
CBM = 2(21446.27) = $42892.54

CBM°= 5229.14 [1.89+1.35(1.0) (1.0)] = 16942.41
CBM°= 2(16942.41) = $33884.82
From Table A.5,

𝐶𝐵𝑀
FBM =
𝐶𝑃 °
21446.27
FBM = = 4.10
5229.14
For 2019,
CP°,2019 = 10458.28 (619.2/394) = 16435.96
CBM,2019 = CP°2019FBM = 16435.96 (4.10) = $67387.44
CBM°,2019 = 16435.96 [1.89+1.35(1.0) (1.0)] = $53252.51
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4.1.4 REACTORS
Table 4.1.4.1: Information on Reactors

Equipment Number Capacity/Size Material of Operating
Construction
Pressure (barg)
R-301 Volume = 77.48m3 Stainless Steel 19.7
119

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Table 4.1.4.2: Results of Capital Cost Estimate for Reactor in 2001 (CEPCI, 2001 = 394,
2019 = 619.2)
Equipment FBM Cp° (2001) CBM (2001) CBM° (2001)
R-301 4 1,656.81 6,627.24 1,656.81
R-302 4 1,487.40 5,949.60 1,487.40
R-303 4 986.80 3,947.20 986.80
R-304 4 5,990.06 23,960.24 5,990.06
Total($): 10,121.07 40,484.28 10,121.07
Table 4.1.4.3: Results of Capital Cost Estimate for Reactor in 2019 (CEPCI, 2001 = 394,
2019 = 619.2)
Equipment FBM Cp° (2019) CBM (2019) CBM° (2019)
R-301 4 10,415.20 2,603.80
R-302 4 2,337.55 9,350.23 2,337.55
R-303 4 1,550.83 6,203.32 1,550.83
R-304 4 9,413.82 37,655.28 9,413.82
Total($): 15,906.00 63,624.03 15,906.00
120

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COSTING CALCULATION FOR REACTORS

R-301
Based on heuristic, V of reactor = 77.48 m3
From Table A.1, Reactor jacketed and agitated, K1=4.1052, K2= -0.4680, K3= -0.0005
𝐿𝑜𝑔 𝐶𝑃 ° = 𝐾1 + 𝐾2 𝑙𝑜𝑔10 (𝑉𝑜𝑙𝑢𝑚𝑒, 𝑚3 ) + 𝐾3 [𝑙𝑜𝑔10 (𝑉𝑜𝑙𝑢𝑚𝑒, 𝑚3 )]2
𝐿𝑜𝑔 𝐶𝑃 ° = 4.1052 − 0.4680 log(77.48) − 0.0005 log(77.48)2
CP°,2001 = 1656.81
619.2
CP°,2019 = 1656.81 ×
394
CP°,2019 = 2603.80
From Figure A.7, Reactor jacketed and agitated, FBM = 4

CBM = CP°FBM
CBM,2011 = 1656.81× 4 = 6627.24
Given CEPCI for year 2001 is 394 and CEPCI found for year 2019 is 619.2.
619.2
CBM,2019 = 6627.24 ×
394
CBM,2019 = 10415.195
When FBM = 1
CBM°= CP° FBM
CBM°= CP°
R-302
𝐿𝑜𝑔 𝐶𝑃 ° = 4.1052 − 0.4680 log(97.472) − 0.0005 log(97.472)2
CP°,2011 = 1487.40
619.2
CP°,2019 = 1487.40 ×
394
CP°,2019 = 2337.551
121

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CBM = CP°FBM
CBM,2011 = 1487.40× 4 = 5949.60
619.2
CBM,2019 = 5949.60 ×
394
CBM,2019 = 9350.23
R-303
𝐿𝑜𝑔 𝐶𝑃 ° = 4.1052 − 0.4680 log(233.279) − 0.0005 log(233.279)2
CP°,2011 = 986.80
619.2
CP°,2019 = 986.80 ×
394
CP°,2019 = 1550.83
For FBM from table A.17, Reactor jacketed and agitated, FBM = 4
CBM,2011 = 986.80× 4 = 3947.20
619.2
CBM,2019 = 3947.20 ×
394
CBM,2019 = 6203.32
R-304
Based on Scale Up, V of Reactor = 5.01 m3
𝐿𝑜𝑔 𝐶𝑃 ° = 4.1052 − 0.4680 log(5.01) − 0.0005 log(5.01)2
CP°,2011 = 5990.06
619.2
CP°,2019 = 5990.06 ×
394
CP°,2019 = 9413.82
122

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CBM = CP°FBM
CBM,2011 = 5990.06× 4 = 23960.24
619.2
CBM,2019 = 23960.24 ×
394
CBM,2019 = 37655.28
123

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4.1.5 VESSELS
Table 4.1.5.1: Information on Vessels

(barg)
V-301 Volume= 21 m3 Carbon Steel Discharge = 21
Horizontal 7 m3 (3)
Vessels L/D = 15
D = 1.212 m
D = 0.5447 m Carbon Steel Discharge =
V-302 L = 25.59 m 1.1
Benzene V = 2.981 m3
Condenser Vertical
Demister Pad
V-303 Volume = 23.1 m3 Carbon Steel Discharge =
Horizontal 7.7 m3 (3) 2.05
Vessels L/D = 15
D = 1.252 m
V-304 Volume = 18.6 m3 Carbon Steel Discharge =
Horizontal 6.2 m3 (3) 2.10
Vessels L/D = 15
D = 1.165 m
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Table 4.1.5.2: Results of Capital Cost Estimate for Vessels in 2001 (CEPCI, 2001 = 394,
2019 = 619.2)

V-301 2.92 1.00 5.92 16,367.71 96,852.71 49,266.81
V-302 0.5859 1.0 3.3163 5,014.18 16,628.72 20,407.71
Demister Fp=1 - 1 2,913.49 8,740.47 8,740.47
Pad Fq =
3.00
V-303 0.74 1.00 2.61 17,365.17 45,403.80 52,269.16
V-304 0.73 1.00 2.60 15,195.80 39,472.98 45,739.36
Total($): 56,856.35 207,098.68 176,423.51
2019 = 619.2)

V-301 2.92 1.00 5.92 25,723.06 152,280.52 77,426.41
V-302 0.6070 1.0 3.3547 8,524.18 28,596.08 34,693.41
V-302 0.5859 1.0 3.3163 7,880.15 26,132.94 32,072.21
Demister Fp=1 - 1 4,577.99 13,733.97 13,733.97
Pad Fq =
3.00
V-304 0.73 1.00 2.60 23,881.32 62,091.43 186,895.20
Total($): 70,586.70 282,834.94 344,821.20
125

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COSTING CALCULATIONS FOR VESSELS

V-301 Horizontal Process Vessels
From Table A.1, K1=3.5565, K2=0.3776, K3=0.0905
𝐿𝑜𝑔 𝐶𝑃 ° = 𝐾1 + 𝐾2 𝑙𝑜𝑔10 (𝑉𝑜𝑙𝑢𝑚𝑒) + 𝐾3 [𝑙𝑜𝑔10 (𝑉𝑜𝑙𝑢𝑚𝑒)]2
𝐿𝑜𝑔 𝐶𝑃 ° = 3.5565 + 0.3776 log(21) + 0.0905 log(21)2
CP°,2001 = 16367.71
(P)
Fp = + 0.0035
2[850 − 0.6(P)]
0.0063
(21)
Fp = + 0.0035
2[850 − 0.6(21)]
0.0063
FP = 2.92

From Table A.4, B1=1.49 and B2=1.52 , FM = 1 , FP = 2.92
CBM,2001 = CP° [B1+ B2 (𝐹𝑀 ) (𝐹𝑃 )]
CBM,2001 = 16367.71 [1.49+1.52(1.0) (2.91)]
CBM,2001 = $96852.71

CBM°,2001 = 16367.71 [1.49+1.52(1.0) (1.0)]
CBM°,2001 = 49266.81
From Table A.5,

𝐶𝐵𝑀
FBM =
𝐶𝑃 °
96852.71
FBM = = 5.92
16367.71
For 2019, CP°,2019 = 16367.71 (619.2/394) = 25723.06

CBM,2019 = CP°2019FBM = 25723.06(5.92) = $152280.52
CBM°,2019 = 25723.06 [1.49+1.52(1.0) (1.0)] = $77426.41
126

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V-302
From Table A.1, K1 = 3.4974, K2 = 0.4485, K3 = 0.1074
Log10 Cp° = 3.4974 + 0.4485 log10 (2.7047) + 0.1074 [log10 (2.7047)] 2
Cp°2001 = $5,014.18
(𝑃 + 1)𝐷
+ 0.00315
2[850 − 0.6(𝑃 + 1)]
𝐹𝑝,𝑣𝑒𝑠𝑠𝑒𝑙 =
0.0063
(1.1 + 1)0.4374
+ 0.00315
2[850 − 0.6(1.1 + 1)]
𝐹𝑝,𝑣𝑒𝑠𝑠𝑒𝑙 =
0.0063
𝐹𝑝,𝑣𝑒𝑠𝑠𝑒𝑙 = 0.5859
FBM = [B1 + B2 FM FP] = 2.25+1.82(1) (0.5859)
= 3.3163
CBM ,2001 = Cp° [B1 + B2 FM FP]
CBM ,2001 = $5,014.18 [2.25+1.82(1) (0.5859)]
CBM ,2001 = $16,628.72

CBM°,2001 = 5,014.18 [2.25+1.82(1.0) (1.0)]
CBM°,2001 = $20,407.71
𝐼
For 2019, 𝐶2019 = 𝐶2001 ( 𝐼2019 )
2001
127

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619.2
Cp°, 2019 = $5,014.18 ( ) = $7,880.15
394
CBM, 2019 = Cp°, 2019 FBM = $7,880.15 (3.3163)
CBM, 2019 = $26,132.94
CBM°, 2019 = $7,880.15[2.25+1.82(1.0) (1.0)]
CBM°, 2019 = $32,072.21
Demister Pad:
From Table A.1, K1 = 3.2353, K2 = 0.4838, K3 = 0.3434
Log10 Cp° = 3.2353 + 0.4838 log10 (2.7047) + 0.1074 [log10 (2.7047)] 2
Cp°2001 = $2,913.49
log1𝑜 𝐹𝑞 = 0.4771 + 0.08516 log10 𝑁 − 0.3473(log10 𝑁)2 , N=1
log1𝑜 𝐹𝑞 = 0.4771 + 0.08516 log10 (1) − 0.3473(log10 (1))2
Fq = 3.00
From Figure A.19, FBM = 1 (Identification Number = 63 from Table A.6)
𝐶𝐵𝑀 = 𝐶𝑝𝑜 𝑁𝐹𝐵𝑀 𝐹𝑞
𝐶𝐵𝑀 = (2913.49)(1)(1)(3.00)
𝐶𝐵𝑀 = $8,740.47
𝑜
∗ 𝐶𝐵𝑀 = 𝐶𝐵𝑀 since Fp and FBM = 1
𝐼
For 2019, 𝐶2019 = 𝐶2001 ( 𝐼2019 )
2001
128

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619.2
Cp°, 2019 = $2,913.49 ( ) = $4,577.99
394
CBM, 2019 = Cp°, 2019 FBMFq = $4.577.99 (1) (3.00)
CBM, 2019 = $13,733.97

𝑜
∗ 𝐶𝐵𝑀 = 𝐶𝐵𝑀 since Fp and FBM = 1
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From Table A.1, K1=3.5565, K2=0.3776, K3=0.0905
𝐿𝑜𝑔 𝐶𝑃 ° = 𝐾1 + 𝐾2 𝑙𝑜𝑔10 (𝑉𝑜𝑙𝑢𝑚𝑒) + 𝐾3 [𝑙𝑜𝑔10 (𝑉𝑜𝑙𝑢𝑚𝑒)]2
𝐿𝑜𝑔 𝐶𝑃 ° = 3.5565 + 0.3776 log(23.1) + 0.0905 log(23.1)2
CP° = 17365.17
(P)
Fp = + 0.0035
2[850 − 0.6(P)]
0.0063
(2.05)
Fp = + 0.0035
2[850 − 0.6(2.05)]
0.0063
FP = 0.7399

CBM,2001 = CP° [B1+ B2 (𝐹𝑀 ) (𝐹𝑃 )]
CBM,2001 = 17365.17 [1.49+1.52(1.0) (0.74)]
CBM,2001 = $45403.80

CBM°= 17365.17 [1.49+1.52(1.0) (1.0)]
CBM°= $52269.16
From Table A.5,

𝐶𝐵𝑀
FBM =
𝐶𝑃 °
45403.80
FBM = = 2.61
17365.17
For 2019,
CP°,2019 = 17365.17 (619.2/394) = 27290.64
CBM,2019 = CP°2019FBM = 27290.64 (2.61) = $71228.57
CBM°,2019 = 27290.64 [1.49+1.52(1.0) (1.0)] = $82144.83
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From Table A.1, K1=3.5565, K2=0.3776, K3=0.0905
𝐿𝑜𝑔 𝐶𝑃 ° = 𝐾1 + 𝐾2 𝑙𝑜𝑔10 (𝑉𝑂𝑙𝑢𝑚𝑒) + 𝐾3 [𝑙𝑜𝑔10 𝑉𝑜𝑙𝑢𝑚𝑒]2
𝐿𝑜𝑔 𝐶𝑃 ° = 3.5565 + 0.3776 log( 18.6) + 0.0905 log( 18.6)2
CP° = 15195.80
(P)
Fp = + 0.0035
2[850 − 0.6(P)]
0.0063
(2.1)
Fp = + 0.0035
2[850 − 0.6(2.1)]
0.0063
FP = 0.7287

CBM,2001 = CP° [B1+ B2 (𝐹𝑀 ) (𝐹𝑃 )]
CBM,2001 = 15195.80 [1.49+1.52(1.0) (0.73)]
CBM,2001 = 39472.98

CBM°= 15195.80 [1.49+1.52(1.0) (1.0)]
CBM°= 45739.36
From Table A.5,

𝐶𝐵𝑀
FBM =
𝐶𝑃 °
39472.98
FBM = = 2.60
15195.80
For 2019,
CP°,2019 = 15195.80 (619.2/394) = 23881.32
CBM,2019 = CP°2019FBM = 23881.32(2.60) = 62091.43
CBM°,2019 = 62091.43[1.49+1.52(1.0) (1.0)] = $186895.20
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4.1.6 DISTILLATION COLUMN
2019 = 619.2)
Equipment FP FM Fq FBM Cp° (2001) CBM (2001) CBM° (2001)

T-301 0.79 1.0 3.6878 29,943.80 110,426.75 121,871.27
(Vessel)
T-301 1.0 1.0 1.0 2.0000 1,247.83 96,582.04 53,656.69
(Tray)
T-302 0.8254 1.0 3.7522 32,077.46 189,156.24 130,555.26
(Vessel)
T-302 1.0 1.0 1.0 1.8 1,480.81 146,613.60 51,828,35
(Tray)
Total ($) 64,749.90 542,778.63 306,083.22
2019 = 619.2)
Equipment FP FM Fq FBM Cp° (2019) CBM (2019) CBM° (2019)
T-301 0.79 1.0 3.6878 47,058.89 173,543.76 191,529.68
(Vessel)
T-301 1.0 1.0 1.0 2.0000 1,961.06 151,785.78 84,325.58
(Tray)
T-302 0.8254 1.0 3.6878 50,412.09 189,156.24 205,177.21
(Vessel)
T-302 1.0 1.0 1.0 2.0000 2,327.20 93,291.03 81,452.00
(Tray)
Total ($) 101,759.24 607776.81 562484.47
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COSTING DATA RESULTS FOR DISTILLATION COLUMN

T-301 (Tower)
From Table A.1, K1 = 3.4974, K2 = 0.4485, K3 = 0.1074
Log10 Cp° = K1 + K2 log10 (Volume, m3) + K3 [log10 (Volume, m3)] 2
Log10 Cp° = 3.4974 + 0.4485 log10 (38.26) + 0.1074 [log10 (38.26)] 2
Cp°2001 = $29,943.80
Purchased cost in the year 2019;

619.2
𝐶𝑝° (2019) = $29,943.80 ( ) = $47,058.89
394
(𝑃+1)𝐷 (1.2+1)1.41
+0.00315 +0.00315
2[850−0.6(𝑃+1)] 2[850−0.6(1.2+1)]
FP,vessel =
0.0063
= 0.0063
= 0.79
FBM = [B1 + B2 FM FP] = 2.25+1.82(1) (0.79)
= 3.6878
CBM ,2001 = Cp° FBM
CBM ,2001 = $29,943.80 (3.6878)
CBM ,2001 = $110,426.75

619.2
CBM ,(2019) = $110,426.75 ( ) = $173,543.76
394
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CBM°,2001 = 29,943.80 [2.25+1.82(1.0) (1.0)]
CBM°,2001 = $121,871.27
𝐼
For 2019, 𝐶2019 = 𝐶2001 ( 𝐼2019 )
2001
619.2
Cp°, 2019 = $29,943.80 ( ) = $47,058.89
394
CBM°, 2019 = $ 47,058.89 [2.25+1.82(1.0) (1.0)]
CBM°, 2019 = $191,529.68
T-301 (SS-Sieve Tray)
From Table A.1, K1 = 2.9949, K2 = 0.4465, K3 = 0.3961
Log10 Cp° = 2.9949 + 0.4465 log10 (1.5615) + 0.3961 [log10 (1.5615)] 2
Cp°2001 = $1,247.83

619.2
𝐶𝑝° (2019) = $1,247.83 ( ) = $1,961.06
394
FP, = 0.0
From Figure A.18, FM = 1.8 (Identification Number = 61---- from Table A.3)
FBM= 1.8
Fq=1 for N˃20
CBM ,2001 = Cp° NFBMFq
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CBM ,2001 = $1,247.83 (43) (1.8) (1)
CBM ,2001 = $96,582.04

619.2
CBM(2019) = $96,582.04 ( ) = $151,785.78
394
When 𝐹𝑃 = 1 and FM=1.0, FBM=1

CBM°,2001 = $1,247.83 (43)(1)(1)
CBM° ,2001 = $53,656.69
𝐼
For 2019, 𝐶2019 = 𝐶2001 ( 𝐼2019 )
2001
619.2
Cp°, 2019 = $1,247.83( ) = $1,961.06
394

CBM°, 2019 = $ 1,961.06 (43)(1.0)(1)
CBM°, 2019 = $84,325.58
Bare Module Cost for T-301,

𝐂𝐁𝐌,𝐭𝐨𝐰𝐞𝐫+𝐭𝐫𝐚𝐲𝐬, (𝟐𝟎𝟏𝟗) = 𝐂𝐁𝐌,𝐭𝐨𝐰𝐞𝐫 + 𝐂𝐁𝐌,𝐭𝐫𝐚𝐲
CBM = $173,543.77 + $151,786.04

𝐂𝐁𝐌,𝟐𝟎𝟏𝟗 = $𝟑𝟐𝟓, 𝟑𝟐𝟗. 𝟖𝟏
CBM°,𝐭𝐨𝐰𝐞𝐫+𝐭𝐫𝐚𝐲𝐬, (𝟐𝟎𝟏𝟗) = 𝐂𝐁𝐌,𝐭𝐨𝐰𝐞𝐫 + 𝐂𝐁𝐌,𝐭𝐫𝐚𝐲
CBM° = $191,529.68 + $84,325.58

CBM°, 2019 = $𝟐𝟕𝟓𝟖𝟓𝟓. 𝟐𝟔
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T-302
For Tower:
Based on Table 7.4, given CEPCI for year 2001 is 394 and 2019 is 619.2.
𝜋𝐷 2 𝐿 𝜋(1.61 𝑚)2 (20.5𝑚)
Volume =
4
= = 41.7345 𝑚3
4
From Table A.1, equipment data cost for towers tray and packed is;
𝐾1 3.4974
𝐾2 0.4485
𝐾3 0.1074
From Equation A.1,

𝐥𝐨𝐠 𝟏𝟎 𝐂𝐩° (2001) = 𝐊 𝟏 + 𝐊 𝟐 𝐥𝐨𝐠 𝟏𝟎 (A) + 𝐊 𝟑 [𝐥𝐨𝐠 𝟏𝟎 (𝐀)] 𝟐
𝑙𝑜𝑔10 𝐶𝑝° (2001) = 3.4974 + 0.4485 𝑙𝑜𝑔10(41.7345) + 0.1074 [𝑙𝑜𝑔10 (41.7345 )] 2
𝑙𝑜𝑔10 𝐶𝑝° (2001) = 4.5062
𝐶𝑝° (2001) = 104.5062 = $32,077.46

619.2
𝐶𝑝° (2019) = $32,077.46 ( ) = $50,412.09
394
Table A.3 and Table A.4 shows,

For vertical Carbon Steel (CS) process vessel (inc tower), the identification number is 18.
𝐵1 2.25
𝐵2 1.82
𝐹𝑀 1.00
From Equation A.3;

𝐅𝐁𝐌 = 𝐁𝟏 + 𝐁𝟐 𝐅𝐩 𝐅𝐌
From Equation A.2; 𝑭 (𝑷+𝟏)𝑫

+𝟎.𝟎𝟎𝟑𝟏𝟓
𝟐[𝟖𝟓𝟎−𝟎.𝟔(𝑷+𝟏)]
𝒑,𝒗𝒆𝒔𝒔𝒆𝒍 =
𝟎.𝟎𝟎𝟔𝟑
𝐹 (1.2+1)(1.61)
+0.00315
2[850−0.6(1.2+1)]
𝑝,𝑣𝑒𝑠𝑠𝑒𝑙 =
0.0063
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𝐹 0.0052
𝑝,𝑣𝑒𝑠𝑠𝑒𝑙 = = 0.8254
0.0063
Thus, 𝐅𝐁𝐌 = 2.25 + 1.82(0.8254) (1) = 3.7522
To obtain the Bare Module Cost, Equation 7.6 is used;

𝐂𝐁𝐌 = 𝐂𝐩° 𝐅𝐁𝐌
𝐂𝐁𝐌,𝟐𝟎𝟏𝟗 = ($50,412.09) (3.7522) = $𝟏𝟖𝟗, 𝟏𝟓𝟔. 𝟐𝟒

CBM°,2001 = 32,077.46 [2.25+1.82(1.0) (1.0)]
CBM°,2001 = $130,555.26
𝐼
For 2019, 𝐶2019 = 𝐶2001 ( 𝐼2019 )
2001
619.2
Cp°, 2019 = 32,077.46 ( ) = $50,412.09
394
CBM°, 2019 = $ 50,412.09 [2.25+1.82(1.0) (1.0)]
CBM°, 2019 = $205,177.21
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For Tray:
Based on Table 7.4, given CEPCI for year 2001 is 394 and 2019 is 617.8.
πD2 π(1.61)2
Area = 4
= = 2.0358 m2
4
From Table A.1, equipment data cost for sieve trays is;
𝐾1 2.9949
𝐾2 0.4465
𝐾3 0.3961
From Equation A.1,
𝐥𝐨𝐠 𝟏𝟎 𝐂𝐩° (2001) = 𝐊 𝟏 + 𝐊 𝟐 𝐥𝐨𝐠 𝟏𝟎 (A) + 𝐊 𝟑 [𝐥𝐨𝐠 𝟏𝟎 (𝐀)] 𝟐
𝑙𝑜𝑔10 𝐶𝑝° (2001) = 2.9949 + 0.4465 𝑙𝑜𝑔10(2.0358) + 0.3961 [𝑙𝑜𝑔10 (2.0358 )] 2
𝑙𝑜𝑔10 𝐶𝑝° (2001) = 3.1705
𝐶𝑝° (2001) = 103.1705 = $ 1,480.81

619.2
𝐶𝑝° (2019) = $ 1,480.81 ( ) = $2,327.20
394
From Table A.5,

For sieve trays with N ≥ 20 due to N = 35 trays:
𝐅𝐪 = 1.0
From Table A.6,

For stainless steel (SS) trays, the identification number is 61.
𝐅𝐁𝐌 = 1.8
To obtain the Bare Module Cost for trays, Equation from Table A.5 is used for sieve trays;
𝐂𝐁𝐌 = 𝐂𝐩° 𝐍𝐅𝐁𝐌 𝐅𝐪
𝐂𝐁𝐌,𝐭𝐫𝐚𝐲𝐬𝟐𝟎𝟏𝟗 = ($2327.20) (35)(1.8)(1.0) = $146,613.60

CBM°,2001 = $1,480.81 (35)(1)(1)
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CBM° ,2001 = $51,828.35

𝐼
For 2019, 𝐶2019 = 𝐶2001 ( 𝐼2019 )
2001
619.2
Cp°, 2019 = $1,480.81 ( ) = $2,327.20
394

CBM°, 2019 = $ 2,327.20 (35) (1.0)(1)
CBM°, 2019 = $81,452.00
Bare Module Cost for T-302,

𝐂𝐁𝐌,𝐭𝐨𝐰𝐞𝐫+𝐭𝐫𝐚𝐲𝐬, (𝟐𝟎𝟏𝟗) = 𝐂𝐁𝐌,𝐭𝐨𝐰𝐞𝐫 + 𝐂𝐁𝐌,𝐭𝐫𝐚𝐲
CBM = $189,156.24 + $146,613.60

𝐂𝐁𝐌,𝟐𝟎𝟏𝟗 = $𝟑𝟑𝟓, 𝟕𝟔𝟗. 𝟖𝟒
CBM°,𝐭𝐨𝐰𝐞𝐫+𝐭𝐫𝐚𝐲𝐬, (𝟐𝟎𝟏𝟗) = 𝐂𝐁𝐌,𝐭𝐨𝐰𝐞𝐫 + 𝐂𝐁𝐌,𝐭𝐫𝐚𝐲
CBM° = $205,177.21 + $81,452.00

CBM°, 2019 = $𝟐𝟖𝟔, 𝟔𝟐𝟗. 𝟐𝟏
4.2 GRASSROOT COST
CTM = ∑𝒏𝒊=𝟏 𝑪𝑻𝑴,𝒊 =𝟏. 𝟏𝟖 ∑𝒏𝒊=𝟏 𝑪𝑩𝒎,𝒊

= 1.18(31,908,346.08)
=$37,643,674.24
CGR = CTM + 0.50 ∑𝒏𝒊=𝟏 𝒄𝒐 𝑩𝒎,𝒊

=$37,643,674.24+ 0.50(24,627,098.80)
=$49,957,223.64
=$50,000,000
Hence,
FCI = CGR = $50,000,000
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4.3 COST OF MANUFACTURING PER YEAR

There are many elements that influence the cost of manufacturing chemicals. Manufacturing
cost estimation also was calculated using the CAPCOST software and many reasonable
assumptions were made throughout the process of calculating the manufacturing cost which
will be discussed later. The calculation cost for the manufacturing cost, COMd involved cost of
fixed capital investment, cost of operating labour, cost of utilities and raw materials.
4.3.1 COST OF UTILITIES

Table 4.3.1: Utilities Summary Based on Equipment
Name Total Module Grass Roots Utility Actual Annual Utility

Cost Cost Used Usage Cost
(MJ/h)
E-301 177,980.31 Boil Feed 5,901 103,061.69
300,380.416 Water
E-302 423,724.22 Boil Feed 7,776 135,798.68
605,700.935 Water
E-303 2,413,146,52 Boil Feed 30,240 528,129.73
3,479,618.95 Water
E-304 1,345,869.38 Boil Feed 37,101 648,008.66
2,261,060.56 Water
E-305 758,034.40 Cooling 14,829 63,558.47
1,273,497.79 Water
E-306 151,000.60 Boil Feed 27,327 4,496,440.34
253,681.008 Water
E-307 166,964.77 Cooling 21,828 93,556.83
280,500.814 Water
E-308 107,476.59 High 15,843 3,397,671.02
Pressure
180,560.671 Steam
E-309 105,551.36 Cooling 15,786 67,660.26
177,326.285 Water
P-301 159.754.70 Electricity 60 44,402.69
A/B 251,633.131
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P-302 35,859.71 Electricity 4 2,960.18

A/B 56,658.3428
P-303 35,859.71 Electricity 4 2,960.18
A/B 56,658.3428
P-304 38,368.08 Electricity 5.25 3,885.24
A/B 60,621.5644
P-305 67,387.44 Electricity 10.8 7,992.48
A/B 106,143.434
H- 11,921,996.80 Natural Gas 67,128 12,033,049.51
301 14,067,956.2
Total $17,908,974.59 $23,411,998.5 $21,629,135.96
4.3.1-1 Assumption of Cost Utilities

In order to calculate the usage of the utilities, there are a lot of assumptions that were made to
proceed with the cost of utilities. The following assumptions that were made are:
1. In a plant, not all of the equipment used will include in the utilities. Certain equipment,
it can been assumed that there is no utilities cost needed for the equipment.
2. As for the major equipment, the cost of utility only focusing on the heat exchanger,
pump and furnace in this plant.
3. 9 heat exchanger equipment are being used in this experiment. Each of the heat
exchanger used different utility. There are 5 heat exchanger used boil feed water as the
utility, 3 heat exchanger used cooling water as the utility and one heat exchanger
equipment used high pressure steam as the utility.
4. For the pump, the utility cost is being calculate based on the actual power used by each
of the pump. The rate of calculation is based on the amount of electricity used in power.
5. Furnace is major equipment that used utility, the cost is the most expensive since it used
natural gas as the material.
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In calculating the utility cost, it is also important for the reader to know that cost of common
utilities follows the cost that the CAPCOST software provided, not defined by our group
such as the price of electricity does not follow the tariff rate from Tenaga Nasional Berhad,
the sole and the only electric utility company in Peninsular Malaysia. Another cost
associated such as the cost of steam also does not follow the tariff rate set by water utility
company located in Kulai Jaya, Johor which the Tenaga Nasional Management Berhad
since the plant was proposed to be built in Johor. Hence, the total cost associated with
utilities calculated by CAPCOST are $21,629,135.96.
4.3.1-2 Sample Calculation of the Utility Cost
Heat Exchanger
E-301
Duty= Q= 5901MJ/h
Q = (ṁsteam)(∆Hvap)
5901 = (ṁsteam)(1699.3)kJ/kg
ṁsteam = 34726kg/h = 0.9646kg/s
365𝑑𝑎𝑦𝑠 $3.85
Yearly cost = (0.9646kg/s)×3600s×24h× ×0.88×
𝑦𝑒𝑎𝑟 1000𝑘𝑔
= $103,061.69 / year
E-302
Duty= Q= 7776MJ/h
7776MJ/h = (ṁsteam)(1699.3)kJ/kg
ṁsteam = 4576kg/h = 1.271kg/s
365𝑑𝑎𝑦𝑠 $3.85
= $135,798.68/year
E-303
Duty= Q= 30240MJ/h
30240MJ/h = (ṁsteam)(1699.3)kJ/kg
ṁsteam = 17795.56kg/h = 4.943kg/s
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365𝑑𝑎𝑦𝑠 $3.85
Yearly cost = (4.943kg/s)×3600s×24h× ×0.88×1000𝑘𝑔
𝑦𝑒𝑎𝑟
= $528,129.73/year
E-304
Duty= Q= 37101MJ/h
37101MJ/h = (ṁsteam)(1699.3)kJ/kg
ṁsteam = 21833.11kg/h = 6.065kg/s
365𝑑𝑎𝑦𝑠 $3.85
= $648,008.66/year
E-305
Duty= Q= 14829MJ/h
365𝑑𝑎𝑦𝑠 $0.556
Yearly cost = (14.829GJ/h) ×24h× ×0.88×1000𝑘𝑔
𝑦𝑒𝑎𝑟
= $63,558.47/year
E-306
Duty= Q= 27327MJ/h
365𝑑𝑎𝑦𝑠 $0.556
Yearly cost = (27.327GJ/h) ×24h× ×0.88×
= $4,396,440.34/year
E-307
Duty= Q= 21828/h
365𝑑𝑎𝑦𝑠 $0.556
Yearly cost = (21.828GJ/h) ×24h× ×0.88×
= $93,556.83/year
E-308
Duty= Q= 15843MJ/h
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365𝑑𝑎𝑦𝑠 $27.82
Yearly cost = (15.843GJ/h) ×24h× ×0.88×1000𝑘𝑔
𝑦𝑒𝑎𝑟
= $3,397,671.02/year
E-309
Duty= Q= 15786MJ/h
365𝑑𝑎𝑦𝑠 $0.556
Yearly cost = (15.786GJ/h) ×24h× ×0.88×
= $67,660.26/year
Pump
*Electric Distribution Cost = $0.096kwh
References= Tarif & Icpt - Tenaga Nasional Berhad
https://www.tnb.com.my/faq/bm-tarif/
P-301 A/B
Power = P=45kW, Efficiency =75%
Electric Power = P/Efficiency = (45)/(0.75)
= 60kW
24ℎ𝑜𝑢𝑟𝑠 365𝑑𝑎𝑦𝑠
Yearly cost = (60kW) ×$0.096/kWh× × ×0.88
𝑑𝑎𝑦𝑠 𝑦𝑒𝑎𝑟
= $44,402.69/year
P-302 A/B
= 4kW
= $2,960.18/year
P-303 A/B
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= 4kW
= $2,960.18/year
P-304 A/B
Power = P=4.2kW, Efficiency =80%
Electric Power = P/Efficiency = (4.2)/(0.80)
= 5.25kW
Yearly cost = (5.25kW) ×$0.096/kWh× × ×0.88
= $3,885.24/year
P-305 A/B
Power = P=8.1kW, Efficiency =75%
Electric Power = P/Efficiency = (8.1)/(0.75)
= 10.8kW
Yearly cost = (10.8kW) ×$0.096/kWh× × ×0.88
= $7,992.48/year
Fired Heater (Furnace)

H301
Required heat load, Q = 67128 MJ/h, Efficiency = 75%
*Natural gas cost (2019) = $17.44/Gj
Yearly cost = (Q) ×Cost× × ×SF/Efficiency
= (67.128Gj/h) ×$17.44/Gj× × ×(0.88)/(0.75)
= $12,033,049.51/year
Therefore, the total cost of utilities is $21,629,135.96/year.
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4.3.2 COST OF LABOR

0.5
𝑁𝑂𝐿 = (6.29 + 31.7𝑃2 + 0.23𝑁𝑛𝑝 )
Where,
NOL = number of operating shifts
P = number of processing steps involve
Nnp = number of non-particulate processing steps
Table 4.3.2: Numbers of Non-Particulate Processing Steps with Different

Type of Equipment
Equipment Number of
Nnp
Type Equipment
Compressor 0 0
Exchanger 9 9
Reactor 4 4
Tower 2 2
Pump* 10 10
Mixer 0 0
Furnace 1 1
Vessel* 2 2
Total 16
*Pumps and vessels are not counted in evaluating Nnp
P2 = 0 because there are no particulate processing steps in this process.
0.5
𝑁𝑂𝐿 = (6.29 + 31.7𝑃2 + 0.23𝑁𝑛𝑝 )
𝑁𝑂𝐿 = (6.29 + 31.7(0)2 + 0.23(16))0.5

𝑁𝑂𝐿 = 3.16
A year consists of 52 weeks. A single operator will work on average of 40 weeks per year
with 45 days off on 8 hours per shift and 5 shift per week.
Usually a chemical plant operates for 24 hours so it requires 3 shift per day for 320 days.
Thus,
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(40 𝑤𝑒𝑒𝑘𝑠/𝑦𝑒𝑎𝑟) 𝑥 (5 𝑠ℎ𝑖𝑓𝑡𝑠/𝑤𝑒𝑒𝑘) = 200 𝑠ℎ𝑖𝑓𝑡𝑠/𝑦𝑒𝑎𝑟
(320 𝑠ℎ𝑖𝑓𝑡𝑠/𝑦𝑒𝑎𝑟) 𝑥 (3 𝑠ℎ𝑖𝑓𝑡𝑠/𝑑𝑎𝑦) = 960 𝑠ℎ𝑖𝑓𝑡𝑠/𝑦𝑒𝑎𝑟
For a single shift,

(960 𝑠ℎ𝑖𝑓𝑡𝑠/𝑦𝑒𝑎𝑟) / (200 𝑠ℎ𝑖𝑓𝑡𝑠/𝑦𝑒𝑎𝑟) = 4.80 𝑜𝑝𝑒𝑟𝑎𝑡𝑜𝑟𝑠
Hourly rate for a single operator,

Monthly payment for an operator, RM4000 (Source: www.payscale.com)
ℎ𝑜𝑢𝑟𝑠 𝑠ℎ𝑖𝑓𝑡𝑠 𝑤𝑒𝑒𝑘𝑠 ℎ𝑜𝑢𝑟𝑠
8 ×5 ×4 = 160
𝑠ℎ𝑖𝑓𝑡𝑠 𝑤𝑒𝑒𝑘𝑠 𝑚𝑜𝑛𝑡ℎ 𝑚𝑜𝑛𝑡ℎ
Hourly rate:
𝑚𝑜𝑛𝑡ℎ 𝑅𝑀4000 𝑅𝑀25
× =
160 ℎ𝑜𝑢𝑟𝑠 𝑚𝑜𝑛𝑡ℎ ℎ𝑜𝑢𝑟
Operating Labour = (operator needed by plant at any time) × (number of labours per shift)
= (4.8) × (3.16)
= 15.16 ≈ 16 operators
𝑅𝑀25 ℎ𝑜𝑢𝑟𝑠 𝑑𝑎𝑦
𝐶𝑂𝐿 = ×8 × 320 × 16 𝑜𝑝𝑒𝑟𝑎𝑡𝑜𝑟𝑠
ℎ𝑜𝑢𝑟 𝑠ℎ𝑖𝑓𝑡.𝑑𝑎𝑦 𝑦𝑒𝑎𝑟
𝐶𝑂𝐿 = 𝑅𝑀1,024,000/𝑦𝑒𝑎𝑟
= $246,210,50
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4.3.3 COST OF RAW MATERIAL
Estimation of Raw Material Price Annually

Raw Material Flowrate Cost Total Cost
(kg/year) (RM/kg) (RM/year)
Ethylene 68909707.8 7.56 520,957,391.00
Benzene 199846417.7 4.13 825,365,705.10
TOTAL - - 1,346,323,096.00
(Source: www.alibaba.com)
Ethylene:
619.2 $
𝐶2019 = 1.202 ( )
394 𝑘𝑔
$1.8890
𝐶2019 =
𝑘𝑔
Flowrate, kg/year:
𝑘𝑔 ℎ𝑟 𝑘𝑔
7866.405 × 8760 = 668909707.8
ℎ𝑟 𝑦𝑟 𝑦𝑟
Cost, $/year,
𝑘𝑔 $ $
668909707.8 × 1.8890 = 130,170,438.00
𝑦𝑟 𝑘𝑔 𝑦𝑟
Convert $/year to RM/year:

$ 𝑅𝑀4.16 𝑅𝑀520,957,391.00
130,170,438.00 × =
𝑦𝑟 $ 𝑦𝑟
Benzene:
619.2 $
𝐶2019 = 0.657 ( )
394 𝑘𝑔
$1.0325
𝐶2019 =
𝑘𝑔
Flowrate, kg/year:
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𝑘𝑔 ℎ𝑟 𝑘𝑔
22813.518 × 8760 = 199846417.7
ℎ𝑟 𝑦𝑟 𝑦𝑟
Cost, $/year,
𝑘𝑔 $ $
199846417.7 × 1.0325 = 206,341,426.3
𝑦𝑟 𝑘𝑔 𝑦𝑟
Convert $/year to RM/year:

$ 𝑅𝑀4.16 𝑅𝑀825,365,705.10
206,341,426.3 × =
𝑦𝑟 $ 𝑦𝑟
Total Cost of Raw Material:

𝐶𝑡𝑜𝑡𝑎𝑙 = 𝐶𝑏𝑒𝑛𝑧𝑒𝑛𝑒 + 𝐶𝑒𝑡ℎ𝑦𝑙𝑒𝑛𝑒
𝐶𝑡𝑜𝑡𝑎𝑙 = 𝑅𝑀 825,365,705.10 + RM520,957,391.00

𝐶𝑡𝑜𝑡𝑎𝑙 = 𝑅𝑀 1,346,323,096.00
Therefore, the total cost of raw material is $336,511,864.30
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4.4 COST OF REVENUE PER YEAR

Production of Ethylbenzene = 250,676.16 tonne/year
Based on the Zhonglan Industries market value prize 1.500 to 2.000 per kg of ethylbenzene
price. We take the prices at between the market value prices.
C2019 = $1.83504/kg
= $1835.04/tonne
Cost of production = $1835.04/tonne × 250,676.16 tonne/year
= $460,000,000/year
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4.5 LAND COST

The start-up location for the plant is very important aspect in order to build a plant design for
the production of Ethylbenzene. The selected location for the production of Ethylbenzene is
Tanjung Langsat Industrial Land, Pasir Gudang, Johor. The land area in this location is about
10 acres and would cost about RM 11,323,600, which is about $2,733,672.53. (iProperty,
2019). This property is about 2 km from Tg Langsat Port and about 7 km from Pasir Gudang
Industrial Area with driving distance of 8 mins and 10 mins respectively. It is accessible via
Pasir Gudang Highway, Senai-Desaru Highway and Eastern Coastal Highway. The main
industries are transportation and logistics, shipbuilding, petrochemicals, also oil palm storage
and distribution.
Figure 4.5-1: Location of land property in Tanjung Langsat, Pasir Gudang, Johor
Figure 4.5-2: Actual on-site photo of the land property
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4.6 Cost of Manufacturing (COM) Summary Assumptions
In order to calculate the cost of manufacturing associated to build a plant, one must know the
cost of raw material itself. For the raw material, we have done some research. From the internet,
it seems that in Malaysian Chemical industry supplier sells the raw material more expensive.
After making some comparing with others country raw material prices. The price is higher in
Malaysia.
In case that, we searched a supplier company from the others country and found a supplier with
the affordable price for the raw material. This company was located and based in China named
as Zhonglan Industry. So, the price value of the raw Material for Ethylene and Benzene is
totally referring to this supplier price. It is affordable for us to buy in a huge amount of raw
material from them.
After that, the price value for the ethylbenzene is also been refer to this industry company. The
price value of selling the chemical product is between 1.5 to 2.0 of ethylbenzene per kg. We
take have of the range value price to be sell towards the consumer. After making some
calculation the it is worth for this company to gain profit.
The price of land is $2,723,000 for 10 acres since the plant was proposed to be located in Pasir
Gudang, Johor. This is the standard price value at Pasir Gudang, Johor. The taxation rate
follows the Malaysia corporate taxation rate which is at 28%. The annual interest rate is 3.95%
which is the rate for the central bank for this country and the salvage value is assuming $0.
Then, from the execution of CAPCOST software, these values are calculated
Description Cost ($)

1.0 Total Bare Module Cost (CBM) $31,901,418.85
2.0 Total Module Cost (CTM) $37,643,674.24
3.0 Grass root Cost (CGR) $50,000,000.00
4.0 Utility Cost (CUT) $21,629,135.96
5.0 Fixed Capital Investment (FCIL)=Grass root Cost (CGR) $50,000,000.00
6.0 Raw Material Costs (CRW) $336,511,864.30
7.0 Operating Labour Cost (COL) $2,462,105.60
8.0 Cost of Manufacturing (without depreciation) $ 447,932,247.20
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The information given are:

Information Value
1. Salvage Value $0
2. Taxation Rate 28%
4. Internal Interest Rate 3.95%
3. Land Cost $2.73M
4. Working Capital (20%FCI) $10,000,000
Also, in calculating the utility cost, it is also important for the reader to know that cost of
common utilities follows the cost that the CAPCOST software provided, and it is not defined
by our group such as the price of electricity does not follow the tariff rate from Tenaga Nasional
Berhad, the sole and the only electric utility company in Peninsular Malaysia. Another cost
associated such as the cost of steam also does not follow the tariff rate set by water utility
company located in Pasir Gudang, Johor since the plant was proposed to be built Pasir Gudang,
Johor.
Another important aspect that needs to be discussed in the assumption made to estimate the
manufacturing cost is the cost of operating labour, which it will be also calculated by the
CAPCOST in which the cost of operating labour is at $48,000/year. This does not follow the
data from Labour Force and Social Statistics provided by the Department of Statistic Malaysia
which is more relevant if one decided to follow the cost of labour using the statistic provided
since the plant is proposed to be located in Pasir Gudang. Hence, the cost of manufacturing
cost calculated from the CAPCOST without depreciation is $447,932,247.20.
Factors Used in Calculation of Cost of Manufacturing (COMd)

𝐶𝑂𝑀𝑑 = 0.18∙𝐹𝐶𝐼𝐿 +2.76∙𝐶𝑂𝐿 +1.23(𝐶𝑈𝑇 +𝐶𝑊𝑇 +𝐶𝑅𝑀)
Cost($)
FCIL 50,000,000.00
COL 2,462,105.6
CUT 21,629,135.96
CWT 0
CRM 323,709,925.20
COMd $440,562,456.7
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CHAPTER 5: PROFITABILITY ANALYSIS
5.1 Non- discounted & Discounted Cash Flow

Project Life (Years after Start-Up) : 10 years
Construction Period : 2 years
Distribution of Fixed Capital Investment (must sum to one)
End of year One 40%
End of year Two 60%
End of year Three -
End of year Four -
End of year Five -
Depreciation Schedule for MACRS Method for Equipment

Year Depreciation Allowance
(% of Capital Investment
1 20.0
2 32.0
3 19.20
4 11.52
5 11.52
6 5.76
Source : Textbook
Land Cost $2.723M

Fixed Capital
Investment, FCI $50M
Working capital $10M
Revenue $450M
Cost of Manufacturing,
COMd $437.162M
Internal Investment Rate 3.95$
Source: Central Bank
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5.2 Tax Rate
The percentage for Malaysia Personal Income Tax Rate is 28%. The average rate from 2004
until 2018 is 27.07%, reaching an all-time high rate at 28% and low record at 25% in 2015. In
Malaysia, the Personal Income Tax Rate is a tax collected from individuals and is imposed on
different sources of income like labour, pensions, interest and dividends. Revenues from this
tax rate are an important source of income for the government of Malaysia.
(Tradingeconomics.com, 2019)
Figure 4.5-1: Malaysia Personal Income Tax Rate from 2010-2018
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Table 5.1 of Production Cash Flow Diagram

n I Dk FCI R COMd (R- Cash Flow Cash Flow Cumulative Cumulative
comd- Non- Discounted Non- cash flow
dk)(1- Discounted ($) discounted Discounted
t)+dk ($) cash flow ($)
($)
0 (2.723) 50 (2.723) -2.723 (2.723) -2.723

1 (20) 50 (20) -21.860 (22.723) -25.446
2 (40) 50 (40) -58.047 (62.723) -88.169
3 10 40 460 440.562 16.795 16.795 -40.888 (45.928) -134.097
4 16 24 460 440.562 18.475 18.475 -23.511 (27.452) -161.549
5 9.6 14.4 460 440.562 16.684 16.683 -8.873 (10.769) -172.318
6 5.76 8.64 460 440.562 15.608 15.608 3.836 4.8392 -167.479
7 5.76 2.88 460 440.562 15.608 15.608 15.591 20.447 -147.031
8 2.88 0 460 440.562 14.802 14.801 25.855 35.249 -111.782
9 0 460 440.562 13.995 13.995 34.749 49.245 -62.538
10 0 460 440.562 13.995 13.995 42.929 63.240 0.702
11 0 460 440.562 9.243 9.243 47.333 72.483 73.186
12 12.723 0 460 440.562 9.243 21.966 59.334 94.450 167.635
Table 5.2. The discounted profitability criterion and non-discounted criterion

Discounted Profitability Criterion Non-discounted Profitability Criterion
Net Present Value, 167.635 Cumulative Cash 1.66409
NPV Ratio, CCR
($millions)
Discounted Cash 11.267 Rate of Return on 18.89
Flow Rae of Return, Investment, ROROI
DCFROR (%) (%)
Discounted Payback 6.449 Payback Periods, 2.883
Periods, DPB (years) PBP (years)
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Cumulative Non-Discounted Cash Flow

80
60
40
Cumulative Cash Flow ($Million)
20
0
0 2 4 6 8 10 12
-20
-40
-60
-80
time (year)
Figure 5.1- Non-discounted graph
Cumulative Discounted Cash Flow

80
Cumulative Cash Flow ($Million)
60
40
20
0
0 2 4 6 8 10 12 14
-20
-40
-60
-80
time (year)
Figure 5.2- Discounted Graph
Based on Table 5.1, Table 5.2, and Figure 5.1, the net present value calculated is $167.635
million. The non-discounted cash flow rate of return, ROROI exceeds the assigned hurdle rate
(15%), which is 18.89% and the payback period is 2.883 years.
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5.3 Sample Calculation
+𝑣𝑒 𝑐𝑎𝑠ℎ 𝑓𝑙𝑜𝑤 1

ROROI = 𝑛(𝑦𝑒𝑎𝑟𝑠) −
𝑛
𝐹𝐶𝐼
144.4496 1
= 10 −
10
50
= 0.1889
𝑆𝑢𝑚 𝑜𝑓+𝑣𝑒 𝑐𝑎𝑠ℎ 𝑓𝑙𝑜𝑤

CCR =
𝑆𝑢𝑚 𝑜𝑓−𝑣𝑒 𝑐𝑎𝑠ℎ 𝑓𝑙𝑜𝑤
157.1726
=
94.4496
= 1.66409
Payback period
= the most –ve value for cumulative ash flow + FCI
= -62.723 + 50
= -12.723
Then, interpolated the data for the cumulative cash flow between year 6 and 7.
−27.4523 − (−12.7230) 4 − 𝑥
=
−27.4523 − (−10.7689) 4 − 5
X = 4.883 years , PBP = 4.883 – 2
Hence the payback period is 2.883years
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6.0 CONCLUSION
From the profitability analysis, the net present value calculated is $167.635million. The
discounted cash flow rate of return, DCFROR within the range of the assigned hurdle rate
(15%), which is 11.267%, and the payback period is 6.49 years. For non-discounted cash flow,
rate of return, ROROI exceeds the assigned hurdle rate which is 18.89$ and the payback period
is 2.88 years.
From the DCFROR, when compare the value with the Internal Interest Rate, IRR. The
value of DCFROR is 11.67% which is higher than the value of IRR, 3.95%. From this
comparison, it seems that the project will gain profit in the life project time because the
DCFROR is more than IRR and within the range of the hurdle rate (15%). The DCFROR value
obtained is more than the Malaysian Interest Rate and the value almost the same as others
country investment rate which is the country are more stable in their economy. So the project
will be run perfectly in returning of the investment and profitable.
In a conclusion that can be made, the project of production of Ethylbenzene is good to

carry on and continue because based on the analysis of the cash flow diagram, the project will
be profitable and increase the production of Ethylbenzene in the world. Thus, it is significantly
relevant to continue the project.
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REFERENCES
1,4-diethylbenzene Thermodynamic & Transport Properties (Based on Mercury model).
(2009). ethermo. Retrieved from
http://www.ethermo.us/Hydrocarbon163Vatemp!653.15!1~press!101.325!2.htm
Behr, A. (n.d.). Experiment Styrene Production from Ethylbenzene.
Davis, S. (2009). CEH Marketing Research Report ETHYLBENZENE.
(2018). Ethyl Benzene Market Present Scenario and Growth Prospects 2018 to 2025. Markets
Insider. Retrieved from https://markets.businessinsider.com/news/stocks/ethyl-
benzene-market-present-scenario-and-growth-prospects-2018-to-2025-1027487950
(2019). Ethyl benzene price. Alibaba. Retrieved from

https://www.alibaba.com/showroom/ethyl-benzene-price.html
Ethylbenzene. (2018). U.S. Secretary of Commerce on behalf of the United States of America.
Retrieved from https://webbook.nist.gov/cgi/cbook.cgi?ID=C100414&Mask=1
(2019). ETHYLBENZENE MARKET - GROWTH, TRENDS, AND FORECAST (2019 - 2024).

Mordor Intelligence. Retrieved from https://www.mordorintelligence.com/industry-
reports/ethylbenzene-market
Felder, R. M., & Rousseau, R. W. (2005). ELEMENTARY PRINCIPLES OF CHEMICAL

PROCESSES. Integrated Media and Study Tools.
Fogler, H. S. (2014). Elements of Chemical Reaction Engineering. Pearson Education Limited

2014.
Garside, M. (2019). Global production capacity of ethylbenzene 2018 & 2023. statista.
Retrieved from https://www.statista.com/statistics/1063696/global-ethylbenzene-
production-capacity/
(n.d.). Global Ethyl Benzene Market Study 2014 - 2025. Prismane Consulting. Retrieved from
https://prismaneconsulting.com/report_details/44/Global-Ethyl-Benzene-Market-
Study-2014---2025
(2019). Malaysia Personal Income Tax Rate. Trading Economics. Retrieved from
https://tradingeconomics.com/malaysia/personal-income-tax-rate
Perry's Chemical Engineer's Handbook, Perry. R.H. (n.d.).
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(2012). Research and Markets: Ethylbenzene Global Market to 2020 - Growth in South and
Central America to Outpace China, While Asia-Pacific Continues to be the Major
Volume Contributor. Business Wire. Retrieved from
https://www.businesswire.com/news/home/20121205005726/en/Research-Markets-
Ethylbenzene-Global-Market-2020--
Sahoo, P. K. (2011). PRODUCTION OF ETHYLBENZENE BY LIQUID-PHASE BENZENE

ALKYLATION. National Institute of Technology Rourkela.
(2019). STATISTIC. BANK NEGARA MALAYSIA CENTRAL BANK OF MALAYSIA.

Retrieved from http://www.bnm.gov.my/index.php?ch=statistic
(2019). Tanjung Langsat Industrial Land, Pasir Gudang. iproperty. Retrieved from
https://www.iproperty.com.my/property/pasir-gudang/tanjung-langsat-industrial-
land/sale-5701723/
(2017). Top 5 Vendors in the Ethylbenzene Market From 2017 to 2021: Technavio. Business
Wire. Retrieved from
https://www.businesswire.com/news/home/20170606005993/en/Top-5-Vendors-
Ethylbenzene-Market-2017-2021
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Analysis, Synthesis, and Design of Chemical. Pearson Education.
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Report MINI Project Plant Design Ethylbenzene

Heat and Mass Transfer Laboratory (Universiti Teknologi MARA)

Studocu is not sponsored or endorsed by any college or university

FACULTY OF CHEMICAL ENGINEERING

PLANT DESIGN AND ECONOMICS (CPE604)

AHMAD ASYRAAF BIN SHAHRIZAMAN 2017632152

Downloaded by Chan Yong Soon (chanyongsoon490@gmail.com)

1.3.3 Liquid Phase Zeolite Catalyst Process ............................................................................ 8

1.4 PROCESS DESCRIPTION ........................................................................................................ 11

2.2.1 R-301 ................................................................................................................................. 25

2.2.3 R-303 .................................................................................................................................. 27

2.2.4 V-302 ................................................................................................................................. 28

2.2.6 T-302 .................................................................................................................................. 30

2.3 ENERGY BALANCE................................................................................................................. 31

2.3.3 R-303 .................................................................................................................................. 49

2.3.5 T-301 .................................................................................................................................. 57

2.3.5 T-302 .................................................................................................................................. 60

2.3.6 V-302 ................................................................................................................................. 63

Downloaded by Chan Yong Soon (chanyongsoon490@gmail.com)

3.3 HEURISTIC FOR R-303 ............................................................................................................ 74

4.1.1 HEAT EXCHANGER ..................................................................................................... 98

4.1.3 PUMP ............................................................................................................................... 112

4.1.4 REACTOR ...................................................................................................................... 119

4.1.6 DISTILLATION COLUMN ........................................................................................ 132

4.3 COST OF MANUFACTURING PER YEAR .......................................................................... 140

4.3.1 COST OF UTILITIES ................................................................................................... 140

4.3.3 COST OF RAW MATERIAL ...................................................................................... 148

4.4 COST OF REVENUE ............................................................................................................... 150

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CHAPTER 1: PROCESS BACKGROUND AND SELECTION

Ethylbenzene is an organic compound with the formula (C6H5CH2CH3) also known as

It is used as a solvent for aluminium bromide in anhydrous electro deposition of

1.2.1 PHYSICAL PROPERTIES

Under ordinary conditions, ethylbenzene is a clear, colourless liquid with a

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irritation to the eyes and skin adsorption. The physical properties of

Table 1.1: Physical properties of Ethylbenzene

1.2.2 CHEMICAL PROPERTIES

Chemically, it is a monocyclic alkyl aromatic compound with a 106 of

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The production by products is reduced if the temperature is gradually lowered

1.3 PROCESS SELECTION

Currently, almost all ethylbenzene is produced commercially by alkylating benzene

𝐶6 𝐻6 + 𝐶2 𝐻4 → 𝐶6 𝐻5 𝐶𝐻2 𝐶𝐻3 Eq. (1.1)

SIDE REACTION EQUATION

𝐶6 𝐻6 + 2𝐶2 𝐻4 → 𝐶6 𝐻4 (𝐶2 𝐻5 )2 1.2

𝐶6 𝐻5 𝐶𝐻2 𝐶𝐻3 + 𝐶2 𝐻4 → 𝐶6 𝐻4 (𝐶2 𝐻5 )2 1.3

𝐶6 𝐻6 + 𝐶6 𝐻4 (𝐶2 𝐻5 )2 → 2𝐶2 𝐻5 𝐶𝐻2 𝐶𝐻3 1.4

1) Liquid Phase Aluminium Chloride Catalyst: Friedel-Crafts/Alcar

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3) Liquid Phase Zeolite Catalyst Process

1.3.1 Liquid Phase Aluminium Chloride Catalyst: Friedel-Crafts/Alcar Process

One method of creating EB is through a Friedel-Crafts reaction of ethylene and

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1.3.2 Vapour-Phase Zeolite Catalyst: Mobil/Badger Process

The vapour-phase reaction to create ethylbenzene using a zeolite catalyst is

Figure 1-2: Alkylation of Benzene and Ethylene to Form EB with Zeolite

Approximate operating conditions are 675-725 K and 200-400 psig. The