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Cumene Production Design

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by

Jay Liu

on 11 July 2013

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Transcript of Cumene Production Design

Future Work, Timeline
& Recommendation

Cumene Production Design
Process Economics
Chief Technology Officer
Senior Process Engineers
Financial Analysts

Purpose: Produce 50,000 tonnes per year of
99.9 wt% cumene
Background
Process Flow Diagram
The Process of Cumene Production
Heat Integration Continuing...
Heat Integration
Packed Bed Reactor
Separation
Second Separation
Storage
& Mixing
Substances stored in flowing roof storage tank
Propylene/Benzene stored at 15/1 atm
Propylene pumps up to 29.6 atm before entering the mixer
Benzene feed and recycle stream pump up after the mixer
Mixing is done at constant pressure
High pressure steam vaporizes reactor inlet
The reactor inlet is partially heated with the reactor outlet
Furnace finishes the heating to 350 °C
Valve drops the cooled reactor outlet to atmospheric pressure
CW cools the reactor outlet to 50 °C
Specifications:
350 °C, 29.6 atm
400 3” tubes, each 16 ft long
Packing amount
3 mm diameter catalyst particles
Cooling jacket with adjustable flowrate
Heat duty is -1401 kW
Yield of 98.4%
Two flash drums remove some propane and propylene
First column has 10 trays and a reboiler
Light key is benzene (goes to recycle)
Partial condenser splits distillate into benzene and remaining propane/propylene gas
Heavy key is cumene
Reflux ratio of 1.15 and reboiler duty of 875 kW
Second column has 15 trays, with a total condenser and reboiler
Light key is cumene
Heavy key is DIPB
Reflux ratio of 2.12 and reboiler duty of 1,563 kW
Start-Up
Start-Up, Safety& Environment
Furnace will completely heat the feed until reactor outlet reaches steady-state temperature
Increase feed flow rate until recycle stream reaches steady-state values

Separation columns run at total reflux until purity requirements are met
First Part-Start Up
Second Part-Start Up
Goal: Inherently safe process
Propylene acts as an asphyxiant
Benzene, cumene, and DIPB are all carcinogenic
Benzene is the most dangerous to the body
Plant workers should avoid contact with all chemicals present
All chemicals present are flammable
High pressure environment requires specialized equipment(Passive strategy)
Exothermic reaction requires effective cooling(limitation of effects)
Safety
Propane and propylene waste are burned in the pre-reactor furnace
Benzene is recycled and not exposed to the environment



DIPB is the only waste stream put into the environment
Benzene, cumene, and DIPB cannot enter groundwater
Any spilled material should be absorbed with non-combustible material
Environment
Future Work
Timeline
Recommendation
Detailed Design
Resolve specifics of heat integration
Incorporate safety relief valves and control systems
Develop full P&ID

Pilot plant to evaluate the separations
Reaction is well understood
Separations may not operate as expected
Pilot plant will validate separation scheme for use on a large scale

Three months to develop detailed design items
Six months for constructing and operating the pilot plant
Two years for full plant construction
Plant is scheduled to operate for a minimum of twenty years
Profitability is reached at the end of two years of operation
Cost Summary
NPV: $47,690,000
IRR: 45.0%
Cash Flow Analysis
Propylene
52.6 kmol/hr
Benzene
50 kmol/hr
Fuel Gas
4.61 kmol/hr
Cumene
47.9 kmol/hr
DIPB
0.69 kmol/hr
Brandon
Jay&Brain
Allen&Josh
Full transcript