Process Synthesis & Design

(CHEN3003)

INDIVIDUAL PROJECT / SEMESTER 2, 2017

“I declare that this report is solely my own work. All contributions made by others have been duly
acknowledged.”

Perth ID Miri ID Student’s Name Signature

19352570 700025811 Rafael Damar Arjanggi

Course : Chemical Engineering

Name of Lecturer : Zeinab Abbas Jawad
Due Date : November 9, 2017
Submission Date : November 9, 2017
Executive Summary

Heptene is produced by reacting propylene with butene. The fundamental task of this
report is to replicate an existing simulation of heptene production. In this case, propene is
produced by reacting propene with butane accompanied with a catalyst. The simulation is
referenced from Appendix B, section B.11 of the book “Analysis, Synthesis and Design of
Chemical Processes, Third Edition” by Richard Turton (et al.). Replication is executed using
Aspen HYSYS software.

The second part of this report examines the simulation results. Major discrepancies are
reviewed with explanation of the occurrence. The implications of made decisions that cause the
discrepancy are also taken into notice.

In the final part, a chosen extension study on heat exchanger network of the process is
explored. Several network design options are presented and economic comparisons are made to
help justify the chosen design. Moreover, the selected design is further validated with calculations.

It is concluded that Design 5 is the best design as it has the lowest cost compared to other
gathered alternatives. This design provides minimum use of utility and effectively removes a
cooling unit from the base case.

i
Contents

Executive Summary .................................................................................................................................... i

List of Figures ............................................................................................................................................ iii
List of Tables .............................................................................................................................................. iii

1. Replication of Existing Simulation.................................................................................................... 1

1.1 Process Description ................................................................................................................... 1
1.2 Simulation Result ....................................................................................................................... 2
1.2.1 Process Flowsheet (HYSYS)............................................................................................ 2
1.2.2 Stream Table....................................................................................................................... 1
1.3 Judgement Calls and Problem Dealing Decisions ................................................................ 3

2. Checking of Simulation Result ......................................................................................................... 5

3. Extension Study: Heat Exchanger Network ................................................................................... 5

3.1 Scope ........................................................................................................................................... 5
3.2 Analysis ........................................................................................................................................ 6
3.2.1 General Four Stream Flowsheet Method ....................................................................... 6
3.2.2 Manual Modification Method ............................................................................................. 8
3.3. Comparison, Selection, and Implication ............................................................................... 10
3.4 Validation of Selected Design ................................................................................................ 11
3.5 Synthesis of Selected Design................................................................................................. 15

4. References ........................................................................................................................................ 16

Appendices................................................................................................................................................ 17
Appendix A: Input Summary.......................................................................................................... 17

ii
List of Figures
Figure 1 Process Flow Diagram of Heptene Production Process............................................ 1
Figure 2 Resulting HYSYS Simulation Flowsheet ................................................................... 2
Figure 3 Four Stream Flowsheet ............................................................................................ 6
Figure 4 Grid Diagram of Base Case (Design 0) .................................................................... 7
Figure 5 Grid Diagram of Design 1 ......................................................................................... 7
Figure 6 Grid Diagram of Design 2 ......................................................................................... 8
Figure 7 Grid Diagram of Design 3 ......................................................................................... 8
Figure 8 Manually Modified Flowsheet (Design 4) .................................................................. 9
Figure 9 Grid Diagram of Modified Flowsheet Base Case (Design 4) ..................................... 9
Figure 10 Grid Diagram of Design 5...................................................................................... 9
Figure 11 Grid Diagram of Design 6.....................................................................................10
Figure 12 Composite Curve of Process Stream ...................................................................11
Figure 13 Flowsheet of selected Heat Exchanger Network (Design 5) .................................12
Figure 14 Overall Process Flowsheet Applied with Selected Heat Exchanger Network .......15

List of Tables
Table 1 Resulting HYSYS Simulation Stream Table.............................................................. 1
Table 2 Decision and Reasoning of Matters Faced ............................................................... 3
Table 3 Operational Cost of All Designs Relative to Design 0 ..............................................10
Table 4 Capital Cost, Payback, & Energy Saving of Design 1, 2, & 3 Relative to Design 0 ..10
Table 5 Capital Cost, Payback, & Energy Saving of Design 5 and 6 Relative to Design 4 ....11
Table 6 Heat Capacity of Components .................................................................................12
Table 7 Calculation of Stream 4 Heat Capacity Fraction ......................................................13
Table 8 Calculation of Stream 14a Heat Capacity Fraction ..................................................14

iii
1. Replication of Existing Simulation

1.1 Process Description

Initially, two liquid streams containing propylene and butane are mixed along with a
negligible amount of catalyst stream at 8 bar. The catalyst used is organometallic, carried with a
small volume of hexane. The desired product of this reaction is 1-heptene. However, there are
four primary reactions that occur inside the reactor, resulting in several undesired product.

Reaction 1

Reaction 2

Reaction 3

Reaction 4

This situation requires three distillation columns to separate all the components.
Specifically, the given design depicts a direct sequence of those columns. Design process flow
diagram is displayed in Figure 1.

Figure 1 Process Flow Diagram of Heptene Production Process

Source: Retrieved from Turton, et al. (2012, 138-139)

The simulation by Turton is done through CHEMCAD simulator using SRK VLE and
enthalpy packages. For the replication using HYSYS, choosing the SRK fluid package is fitting to
this process. All components listed are also available in HYSYS.

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1.2 Simulation Result

1.2.1 Process Flowsheet (HYSYS)

Figure 2 Resulting HYSYS Simulation Flowsheet

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1.2.2 Stream Table

Table 1 Resulting HYSYS Simulation Stream Table

Stream Number 1 1a 2 2a 2b 3 4a
Temperature (°C) 25 22 25 25 25 26 110
Pressure (bar) 11.6 10.6 3.0 9.0 8.0 8.0 8.0
Vapor fraction 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Mass flow (tonne/h) 3.15 3.15 9.29 9.29 9.29 12.44 4.53
Mole flow (kmol/h) 74.57 74.57 163.21 163.21 163.21 237.78 53.42
Component flowrates
(kmol/h)
Propane 3.56 3.56 0.00 0.00 0.00 3.56 0.32
Propylene 71.01 71.01 0.00 0.00 0.00 71.01 0.00
i-Butane 0.00 0.00 29.44 29.44 29.44 29.44 4.37
n-Butane 0.00 0.00 34.41 34.41 34.41 34.41 6.08
i-Butene 0.00 0.00 8.27 8.27 8.27 8.27 1.30
1-Butene 0.00 0.00 90.95 90.95 90.95 90.95 7.19
1-Hexene 0.00 0.00 0.14 0.14 0.14 0.14 9.39
1-Heptene 0.00 0.00 0.00 0.00 0.00 0.00 16.82
1-Octene 0.00 0.00 0.00 0.00 0.00 0.00 5.69
1-Undecene 0.00 0.00 0.00 0.00 0.00 0.00 2.26

Stream Number 4v 4va 4 4b 4c 7a 7

Temperature (°C) 110 11 48 104 96 5 4
Pressure (bar) 8.0 7.7 7.7 7.7 5.8 5.5 5.0
Vapor fraction 1.0 0.0 0.0 0.6 0.7 1.0 1.0
Mass flow (tonne/h) 7.91 7.91 12.44 12.44 12.44 0.13 0.13
Mole flow (kmol/h) 124.70 124.70 178.12 178.12 178.12 3.05 3.05
Component flowrates
(kmol/h)
Propane 3.24 3.24 3.56 3.56 3.56 3.00 3.00
Propylene 0.04 0.04 0.05 0.05 0.05 0.05 0.05
i-Butane 25.07 25.07 29.44 29.44 29.44 0.00 0.00
n-Butane 28.33 28.33 34.41 34.41 34.41 0.00 0.00
i-Butene 6.97 6.97 8.27 8.27 8.27 0.00 0.00
1-Butene 37.75 37.75 44.93 44.93 44.93 0.00 0.00
1-Hexene 11.80 11.80 21.19 21.19 21.19 0.00 0.00
1-Heptene 9.69 9.69 26.52 26.52 26.52 0.00 0.00
1-Octene 1.73 1.73 7.41 7.41 7.41 0.00 0.00
1-Undecene 0.08 0.08 2.34 2.34 2.34 0.00 0.00

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 Table 1 (Continued)
Stream Number 4d 6a 6b 6 8 8a 10a
Temperature (°C) 65 47 47 47 149 142 75
Pressure (bar) 5.8 5.5 7.6 6.6 5.8 4.8 2.0
Vapor fraction 0.0 0.0 0.0 0.0 0.0 0.1 0.0
Mass flow (tonne/h) 12.30 6.66 6.66 6.66 5.64 5.64 1.86
Mole flow (kmol/h) 175.07 116.38 116.38 116.38 58.69 58.69 22.48
Component flowrates
(kmol/h)
Propane 0.56 0.56 0.56 0.56 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00 0.00 0.00 0.00
i-Butane 29.44 29.28 29.28 29.28 0.16 0.16 0.16
n-Butane 34.41 33.66 33.66 33.66 0.75 0.75 0.75
i-Butene 8.27 8.20 8.20 8.20 0.07 0.07 0.07
1-Butene 44.93 44.48 44.48 44.48 0.45 0.45 0.45
1-Hexene 21.19 0.21 0.21 0.21 20.99 20.99 20.78
1-Heptene 26.52 0.00 0.00 0.00 26.51 26.51 0.27
1-Octene 7.41 0.00 0.00 0.00 7.41 7.41 0.00
1-Undecene 2.34 0.00 0.00 0.00 2.34 2.34 0.00

Stream Number 10 10b Hexenes 11 11a 11b 13a

Temperature (°C) 76 70 42 136 137 137 109
Pressure (bar) 4.5 1.7 1.7 2.5 5.0 4.0 1.5
Vapor fraction 0.0 0.0 0.0 0.0 0.0 0.0 0.0
Mass flow (tonne/h) 1.86 1.86 1.86 3.79 3.79 3.79 2.53
Mole flow (kmol/h) 22.48 22.48 22.48 36.20 36.20 36.20 25.74
Component flowrates
(kmol/h)
Propane 0.00 0.00 0.00 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00 0.00 0.00 0.00
i-Butane 0.16 0.16 0.16 0.00 0.00 0.00 0.00
n-Butane 0.75 0.75 0.75 0.00 0.00 0.00 0.00
i-Butene 0.07 0.07 0.07 0.00 0.00 0.00 0.00
1-Butene 0.45 0.45 0.45 0.00 0.00 0.00 0.00
1-Hexene 20.78 20.78 20.78 0.21 0.21 0.21 0.21
1-Heptene 0.27 0.27 0.27 26.24 26.24 26.24 25.45
1-Octene 0.00 0.00 0.00 7.41 7.41 7.41 0.08
1-Undecene 0.00 0.00 0.00 2.34 2.34 2.34 0.00

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 Table 1 (Continued)
Stream Number 13 13b Heptenes 14 14a C8+
Temperature (°C) 109 101 48 153 147 46
Pressure (bar) 4.0 1.2 1.2 2.0 1.7 1.7
Vapor fraction 0.0 0.1 0.0 0.0 0.1 0.0
Mass flow (tonne/h) 2.53 2.53 2.53 1.26 1.26 1.26
Mole flow (kmol/h) 25.74 25.74 25.74 10.46 10.46 10.46
Component flowrates
(kmol/h)
Propane 0.00 0.00 0.00 0.00 0.00 0.00
Propylene 0.00 0.00 0.00 0.00 0.00 0.00
i-Butane 0.00 0.00 0.00 0.00 0.00 0.00
n-Butane 0.00 0.00 0.00 0.00 0.00 0.00
i-Butene 0.00 0.00 0.00 0.00 0.00 0.00
1-Butene 0.00 0.00 0.00 0.00 0.00 0.00
1-Hexene 0.21 0.21 0.21 0.00 0.00 0.00
1-Heptene 25.45 25.45 25.45 0.79 0.79 0.79
1-Octene 0.08 0.08 0.08 7.33 7.33 7.33
1-Undecene 0.00 0.00 0.00 2.34 2.34 2.34

1.3 Judgement Calls and Problem Dealing Decisions

In certain matters, judgement calls have to be made. For the most part, this is done to
avoid unnecessary action and address implicit information provided. In some cases, there are
problems due to difference of software used and no information is specified to go around it.
Creativity has to be involved to deal with the problems faced, and such act requires logical
reasoning.

Table 2 Decision and Reasoning of Matters Faced

Decision Reason or justification (and necessary

No Matter
/Solution details)
1 Simulation of catalyst No Stream flowrate is of negligible amount and is not
(Y/N) listed in the reference stream table.
2 Use of a mixer for Yes Despite not depicted in the reference flowsheet,
stream 1 and 2 in mixing is mentioned to occur and the only way to
simulation (Y/N) generate stream 3 for comparison.
3 Feed tank in No Function of tank is only to contain feed before
simulation (Y/N) entering reactor.
4 Reaction and reactor Conversion It is insisted to select a simplification of the
selection reactor. As no kinetic or equilibrium data is
provided, conversion is the simplest option.
5 Conversion Rates Calculated. Using the PFR Design Equation,
𝑑𝑋
𝐹𝐴0 = −𝑟𝐴
𝑑𝑉

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 by integrating, and inputting given primary
reactant molar flowrate (FA0), assumed volume of
reactor (V), reaction rate (rA) from literature,
conversion (X) can be obtained for corresponding
reaction. This is done as the reference specified
that Plug Flow Reactor is actually the closest
resemblance to the case.
6 Simulation of Cold Substituted Despite, the cold-shot cooling not being
Shot Cooling simulated, the total duty of coolers E-1201 (5 x
846 MJ/h) can be used as the duty of a cooler to
recover the vapour product from conversion
reactor (stream 4v to 4va). After recovery, the
stream (4va) is mixed with the liquid product
stream (4a) to result in stream 4. In fact, stream
4 of the simulation shows almost the exact same
value as the reference.
7 Pressure drop of Mostly 1 bar Unless stated or intended to adjust with the
valves used pressure flags in the reference flowsheet,
pressure drop of 1 bar is accurate to comply with
the desired pressure of most streams.
8 Pressure drop of Mostly 0 bar Unless stated or intended to adjust with the
cooler and heater pressure flags in the reference flowsheet, the
coolers and heaters are considered to be
frictionless thus causing no pressure drop.
9 Selection of distillation Shortcut For the means of simplification, it is wise to
column column consider shortcut column as a viable option.
Moreover, many data have to be obtained for the
functionality of a rigorous column, and validity of
those data can be of concern. The consequence
are stream 5, 9, and 12 cannot be generated for
comparison.
10 Simulation of stream 7 Yes, As the shortcut column cannot generate the
through multiple overhead outlets, stream 7 must be
component extracted before stream 4 enters the column.
splitter This can be achieved using a component splitter.
Vapour pressure and pressure of the streams are
explicitly given in the reference. Splits
specification for stream 7 can be calculated by
referring to the stream table. Fraction of propane
is 0.843 as a result of dividing 3 (propane in
stream 7) with 3.56 (propane in stream 4).
Fraction of propene is 1.0 as stream 4 is intended
to have no propene content.

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 11 Low Key (LK) and LK = low T-1201: LK = 1-butene, HK = 1-hexene
High Key (HK) in boiling point T-1202: LK = 1-hexene, HK = 1-heptene
distillation columns HK = high T-1203: HK = 1-heptene, HK = 1-octene
boiling point
12 HK in distillate and LK Calculated Using formula, LK component flowrate in
in bottoms of bottoms stream divided by the molar
distillation columns 𝐻𝐾 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑖𝑛 𝑏𝑜𝑡𝑡𝑜𝑚𝑠
𝐻𝐾 𝑖𝑛 𝑑𝑖𝑠𝑡𝑖𝑙𝑙𝑎𝑡𝑒 =
𝐵𝑜𝑡𝑡𝑜𝑚𝑠 𝑠𝑡𝑟𝑒𝑎𝑚 𝑚𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒
𝐿𝐾 𝑐𝑜𝑚𝑝𝑜𝑛𝑒𝑛𝑡 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒 𝑖𝑛 𝑑𝑖𝑠𝑡𝑖𝑙𝑙𝑎𝑡𝑒
𝐿𝐾 𝑖𝑛 𝑑𝑖𝑠𝑡𝑖𝑙𝑙𝑎𝑡𝑒 =
𝐷𝑖𝑠𝑡𝑖𝑙𝑙𝑎𝑡𝑒 𝑠𝑡𝑟𝑒𝑎𝑚 𝑚𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒
13 Reflux ratio of Calculated Using formula, R = L/D
distillation columns 𝑅𝑒𝑓𝑙𝑢𝑥 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒
𝑅𝑒𝑓𝑙𝑢𝑥 𝑅𝑎𝑡𝑖𝑜 =
𝐷𝑖𝑠𝑡𝑖𝑙𝑙𝑎𝑡𝑒 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒

Certain judgement calls certainly have an impact towards the resemblance of the simulation
towards the reference, and may even cause significant discrepancies. This is discussed in the
next part of the report, which is the checking of the simulation results.

2. Checking of Simulation Result

Overall, the result of the generated HYSYS simulation is quite closely resembling the
reference. However, the most noticeable difference lies in the temperature of stream 7. As
previously discussed, the use of shortcut column prevents a resembling result for stream 7. This
is due to the fact that component splitter functions solely to redistribute components, unlike
distillation columns where the function is to separate components according to their boiling point.
This makes the outlet temperature of a distillation column dependent on the condenser and
reboiler temperature or duty. In component splitter, the outlet temperature is not as predictable.
This is also why reliable input for a component splitter are vapor pressure and stream pressure.
Despite the temperature, stream 7 still displays a very close resemblance in other criteria’s of the
stream table.
Other difference simply lies on the esthetics. Some streams don’t exist as they are
embedded in the shortcut column and cannot be displayed. Some streams are made to exist
simply as intermediate. Difference of existing units also lie in some parts of the flowsheet. The
rest are considerably minor discrepancies that is still acceptable.

3. Extension Study: Heat Exchanger Network

3.1 Scope

Smith’s Onion Model places business as the central focus of decision making in process
synthesis. Energy consumption contributes quite a significant portion to the operational cost of a
plant (Towler and Sinnot 2012). Furthermore, the uitility fluids themselves may be costly,
depending on the location of the plant. In some parts of the world, strict waste disposal regulations
are applied, which can make the capital and operating costs even greater (Turton et al. 1998)
Reduction of utility energy consumption can be done by recovering waste heat. Generally, this is
done by using process-process heat exchangers.

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 The aim of this study is to provide a lucrative solution by minimizing utility energy cost, whilst
still supplying the necessary amount of heat for the process. Hence, the best option is the one
with the lowest cost at a reasonable payback period. For this study, the underlying hypotheses is
that cost reduction can be achieved by:

A. Reducing cooling and heating utlities

B. Eliminating unnecessary cooling and/or heating unit(s)

The steps taken in conducting this study are based on those hypotheses.

From the simulation base case, there are eleven utility heating and cooling units. However,
six of those units is ommited from the analysis as they are part of the distillation units and definitely
uses utility for optimum control. The cooler E-1201 is also neglected as it is originally a utility
cooler for cold-shot cooling of the five-stage reactor. This leaves three coolers and one heater as
subjects for heat exchanger network analysis

3.2 Analysis

3.2.1 General Four Stream Flowsheet Method

The analysis is conducted by extracting the information of the three coolers and one heater
from the overall process simulation into a separate HYSYS case. This includes the respective
material and energy streams involved. To this point, a four stream flowsheet is constructed as
displayed in Figure 3.

Figure 3 Four Stream Flowsheet

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 Figure 4 Grid Diagram of Base Case (Design 0)

The next step is performed using the Aspen Energy Analyzer (AEA). AEA automatically
calculates the pinch technology targetting and executes the heat exchanger network synthesis.
Prior to that, AEA generates the potential energy saving scenarios. Three design solutions are
suggested by AEA involving adding a process-process heat exchanger in to the system. Figure
5, 6, and 7 displays the grid diagram of the network designs generated by AEA. Note that all the
added exchangers are assumed to have zero pressure drop.

Figure 5 Grid Diagram of Design 1

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 Figure 6 Grid Diagram of Design 2

Figure 7 Grid Diagram of Design 3

From the four stream flowsheet approach, only hypothesis A is performed. Aspen Energy
Analyzer (AEA) cannot generate a possible scenario for modification, thus, the solutions
generated by AEA doesn’t attempt a removal of any heating or cooling unit. However, solutions
are not limited to this method. The next approach is conducted specifically for the means of
complying with hypothesis B.

3.2.2 Manual Modification Method

The next approach is initially done by manual analysis and modification of the four stream
flowsheet. In an attempt to eliminate a heater or a cooler, at least one stream must successfully
exchange heat with another directly towards its target temperature (without requiring additional
utility). However, temperature cross must be avoided. Temperature cross is a situation where
temperature of heat exchanging streams start to traverse. This situation is undesirable as the
productivity of a heat exchanger will significantly diminish (Olivo 2015). Through manual
modification of the flowsheet (displayed in Figure 8), the desired situation can be achieved
through a process-process heat exchange between stream 13b and 4. Stream 13b can directly

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cool down to its’ target temperature without requiring another heater or cooler. When stream 4 is
substituted with other streams, temperature cross warning is notified by HYSYS thus making this
design the only viable option to comply with hypothesis B. Notice that stream 4 goes through the
tube side of the heat exchanger. Commonly, high pressure streams go inside the tubes as they
are less expensive to build robust (Price, R.M. 1999). Since stream 4 has 7.73 bar, compared to
stream 13b at 1.2 bar, such setup is decided.

Figure 8 Manually Modified Flowsheet (Design 4)

Figure 9 Grid Diagram of Modified Flowsheet Base Case (Design 4)

For better optimization, the manually modified flowsheet is further analyzed using AEA as
done in the previous approach. From the flowsheet, two design solutions are suggested by AEA
involving adding another process-process heat exchanger in to the system. Figure 10 and 11
displays the grid diagram of network designs generated by AEA.

Figure 10 Grid Diagram of Design 5

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 Figure 11 Grid Diagram of Design 6

3.3. Comparison, Selection, and Implication

Comparisons made on the designs are strictly on economic factor. Information on costs
and savings are also calculated by HYSYS. Table 3, 4, and 5 display the details acquired from
HYSYS concerning operational and capital cost, as well as payback period. The best option is
highlighted in green.

Table 3 Operational Cost of All Designs Relative to Design 0

Network Hot Utilities Cold Utilities % Flow %

Cost/Yr % Saving
Design (kJ/h) (kJ/h) Reduction (tonne/h) Reduction

0 (Base) 3,827,000 848,000 -- 0.2613 -- 64,018 --

1 3,535,000 556,400 12.5 0.2287 12.5 59,159 7.6
2 3,518,000 538,900 13.2 0.2267 13.2 58,868 8
3 3,752,000 773,500 3.2 0.253 3.2 62,638 2.2
4 3,456,000 476,000 15.9 0.2198 15.9 57,836 9.7
5 3,179,000 199,500 27.7 0.1889 27.7 53,228 16.9
6 3,405,000 425,500 18.1 0.2141 18.1 56,900 11.1

Table 4 Capital Cost, Payback, & Energy Saving of Design 1, 2, & 3 Relative to Design 0
New Extra Energy Saving
Network Extra Payback
Area Capital
Design Shells (year) kJ/h Cost/Yr
(m2) Cost
1 3.4 2 12,453 2.564 583200 4,860
2 5.7 2 13,714 2.665 618100 5,150
3 1.9 1 11,354 8.234 149000 1,380

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Table 5 Capital Cost, Payback, & Energy Saving of Design 5 and 6 Relative to Design 4
New Extra Energy Saving
Network Extra Payback
Area Capital
Design Shells (year) kJ/h Cost/Yr
(m2) Cost
5 4.6 2 13,130 2.851 553000 4,608
6 2.9 1 11,879 12.7 101100 936

Referring back to hypothesis A, the data firmly demonstrates that minimizing utilities can
reduce operational cost. Furthermore, when comparing data of Design 0 and Design 4, it is clear
that eliminating a cooling or heating unit saves cost. This establishes that hypothesis B is valid.
On top of that, in comparison with Design 1, 2, & 3, which are optimizations of Design 0, Design
4 still tops those options by in every category.

Overall, Design 5 leads every category presented. Most notably, its’ high utility reduction
percentage of 27.7% translates to a high cost saving percentage of 16.9%. The margin to the
second best cost saving percentage is 5.8%, which is quite large. Moreover, the payback period
of Design 5 is considerably reasonable at 2.851 years relative to Design 4. It can be inferred that
Design 5 is the best network design for this process

The implication of implementing design 5 into the plant flowsheet is a much more lucrative
process can be achieved due to decreased cost, energy saving, and utility reduction.

3.4 Validation of Selected Design

It possible for a software to still make errors in conclusion and calculations as it is still
designed by humans. Pinch analysis and calculations have to be done to make sure that Design
5 is feasible to operate. In order to do so, a Composite Curve has to be referred to, which is
displayed in Figure 12.

Figure 12 Composite Curve of Process Stream

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 The composite curve is a generated by AEA. For this case, the DTmin used is 10°C which
is appropriate for such industry chemicals (Linhoff and March 1984). It is pointed out by AEA that
the pinch are located at temperatures 58.1 and 48.1°C, the former being the hot pinch and the
latter being the cold pinch.

Figure 13 Flowsheet of selected Heat Exchanger Network (Design 5)

First evaluation is to be conducted on the first exchange, which is between stream 4 and
13b. Considering the aforementioned pinch temperatures, start temperature of stream 4
(48.14°C), and target temperature of stream 13b (48.21°C), it is inferred that the exchange
happens in the hot side of the pinch. In this situation, the rule is for the heat capacity flowrate of
the cold stream (CPC) to be greater than that of the hot stream (CPH).

𝐶𝑃𝐻 > 𝐶𝑃𝐶

Stream 13b, which is the hot stream, is basically 1-heptene. Thus the heat capacity (Cp)
value of 1-heptene can be simply used. On the other hand, stream 4, which is the cold stream, is
a mix of many components. Heat capacity values of components in this process are presented in
Table… All the values are obtained from literatures for condition of liquid phase, isobaric, and an
adequate temperature range around 48.14°C (stream 4 temperature).

Table 6 Heat Capacity of Components

Component Heat Capacity (J/mol.K)

Propane 119.6
Propylene 102
i-Butane 128.4
n-Butane 132.42
i-Butene 89.2
1-Butene 128.6
1-Hexene 194.41
1-Heptene 237
1-Octene 241.21
1-Undecene 329.95

Page | 12
Calculations

𝐶𝑃 = 𝐶𝑝 × 𝑚𝑜𝑙𝑎𝑟 𝑓𝑙𝑜𝑤𝑟𝑎𝑡𝑒

Stream 13b (hot stream)

𝐶𝑃𝐻 = 𝐶𝑝1−ℎ𝑒𝑝𝑡𝑒𝑛𝑒 × 𝑚𝑜𝑙. 𝑓𝑙𝑜𝑤 𝑠𝑡𝑟𝑒𝑎𝑚 13𝑏

𝐶𝑃𝐻 = 237 × 25,74 𝑚𝑜𝑙
𝐶𝑃𝐻 = 6,100,380 𝐽𝑜𝑢𝑙𝑒/𝐾

Stream 4 (cold stream)

𝐶𝑃𝐶 = 𝐶𝑝𝑚𝑖𝑥 × 𝑚𝑜𝑙. 𝑓𝑙𝑜𝑤 𝑠𝑡𝑟𝑒𝑎𝑚 4

To get the 𝐶𝑝𝑚𝑖𝑥 , heat capacity values from Table… is multiplied with the corresponding
component mole fraction within the stream, and then summed. The mole fraction itself is the
component mole flowrate divided by total mole flowrate.

Table 7 Calculation of Stream 4 Heat Capacity Fraction

Mole Cp
Component
flowrate fraction
Propane 3.56 2.388796
Propylene 0.05 0.027246
i-Butane 29.44 21.22227
n-Butane 34.41 25.58157
i-Butene 8.27 4.141516
1-Butene 44.93 32.44054
1-Hexene 21.19 23.13348
1-Heptene 26.52 35.28139
1-Octene 7.41 10.03794
1-Undecene 2.34 4.331745
Total 178.12 158.5865

𝐶𝑃𝐶 = 158.6 × 178,12 𝑚𝑜𝑙

𝐶𝑃𝐶 = 29,241,247.92 𝐽𝑜𝑢𝑙𝑒/𝐾

From the calculation made, it is proven that 𝐶𝑃𝐻 > 𝐶𝑃𝐶 thus confirming the exchange between
stream 13b and 4 to be feasible.

For the second exchange, which is between stream 4 and 14a, the same technique is executed.
The CP value for stream 4 has been obtained. So, calculation for stream 14a is what’s left. Stream
14a is comprised of 1-heptene, 1-octene, and 1-undecene.

Page | 13
Stream 14a (hot stream)

𝐶𝑃𝐻 = 𝐶𝑝𝑚𝑖𝑥2 × 𝑚𝑜𝑙. 𝑓𝑙𝑜𝑤 𝑠𝑡𝑟𝑒𝑎𝑚 14𝑎

Table 8 Calculation of Stream 14a Heat Capacity Fraction

Mole Cp
Component
fraction fraction
1-Heptene 0.79 17.899619
1-Octene 7.33 169.07232
1-Undecene 2.34 73.757027
Total 10.46 242.82935

𝐶𝑃𝐻 = 242.8 × 10.46 𝑚𝑜𝑙

𝐶𝑃𝐻 = 2,540 𝐽𝑜𝑢𝑙𝑒/𝐾

From the second calculation, it is proven that 𝐶𝑃𝐻 > 𝐶𝑃𝐶 thus confirming the exchange between
stream 13b and 4 to be feasible. This indicates that Design 5 is completely feasible to operate.

Page | 14
3.5 Synthesis of Selected Design

Figure 14 Overall Process Flowsheet Applied with Selected Heat Exchanger Network

Page | 15
4. References
Turton, Richard, Richard C Bailie, and Wallace B Whiting. 2012. "Appendix B: Information for the
Preliminary Design of Fifteen Chemical Processes". In ‘Analysis, Synthesis, And Design Of
Chemical Processes, 4th ed.’, 139-146. Upper Saddle River, NJ: Pearson Education
International.

Towler, Gavin P. Chemical Engineering Design: Principles, Practice and Economics of Plant and
Process Design, Second Edition. 2nd ed. Kidlington, Oxford, U.K. ; Waltham, Mass.:
Butterworth-Heinemann, 2013.

Schlinger, W.G.; Sage, B.H., Isobaric heat capacity of 1-butene and 1-pentene at bubble point,
Ind. Ing. Chem 1949

Aston, J.G.; Messerly, G.H., The heat capacity and entropy, heats of fusion and vaporization and
the vapor pressure of n-butane, J. Am. Chem. Soc.: 1940

US Department of Commerce, National Bureau of Standards. 1978. Thermophysical Properties

of Isobutane from 114 to 700 K at Pressures to 70 MPa. Washington D.C.: NBS Publications

Goodwin, R.D., Specific heats of saturated and compressed liquid propane, J. Res. 1978

McCullough, J.P.; Finke, H.L.; Gross, M.E.; Messerly, J.F.; Waddington, G., Low temperature
calorimetric studies of seven 1-olefins: effect of orientational disorder in the solid state, J.
Phys. Chem.: 1957

Chao, J.; Hall, K.R.; Yao, J.M., Thermodynamic properties of simple alkenes, Thermochim. Acta:
1983
︠ IU
︡ riĭ Aleksandrovich Sangalov, Karl Samoĭlovich Minsker, Gennadiĭ Efremovich Zaikov;
Polymers Derived from Isobutylene: Synthesis, Properties, Application. VSP: 2001

Price, R. M. 1999. “RMP Lecture Notes – Shell and Tube Exchanger”.

http://facstaff.cbu.edu/rprice/lectures/shelltube.html

Ollivo, Shannon J. December 8, 2015, comment on Ashutosh Nemani “What is mean by

‘temperature cross’ in heat exchanger?” https://www.quora.com/What-is-mean-by-
temperature-cross-in-heat-exchanger

Dortmund Data Bank GmbH. “Molar Heat Capacity (cP) of 1-Hexene.”

http://www.ddbst.com/en/EED/PCP/HCP_C100.php
Accessed November 9, 2017.

Dortmund Data Bank GmbH. “Molar Heat Capacity (cP) of 1-Heptene.”

http://ddbonline.ddbst.com/DDBSearch/onlineddbovrview.exe?submit=Details&systemcom
Accessed November 9, 2017.

Céondo GmbH. 2016. “Chemical Properties of 1-Octene (CAS 111-66-0)”

https://www.chemeo.com/cid/26-134-4/1-Octene#ref-joback
Accessed November 9, 2017.

Page | 16
Appendices
Appendix A: Input Summary

This Input Summary is generated by HYSYS

Date: Mon Nov 6 18:00:23 UTC+0800 2017

FLUID PACKAGE: Basis-1

Property Package Type: SRK
Component List - 1: / Propane / Propene / i-Butane / n-Butane / i-Butene / 1-Butene / 1-
Hexene / 1-Heptene / 1-Octene / 1-Undecene
ReactionSet Set-2: Rxn-2:
Reactants: Propene, Stoich Coef. = -2 / 1-Hexene, Stoich Coef. = 0.99999166
Rxn-4:
Reactants: Propene, Stoich Coef. = -1 / 1-Butene, Stoich Coef. = -1 / 1-Heptene, Stoich
Coef. = 1
Rxn-6:
Reactants: 1-Butene, Stoich Coef. = -2 / 1-Octene, Stoich Coef. = 1
Rxn-7:
Reactants: Propene, Stoich Coef. = -1 / 1-Butene, Stoich Coef. = -2 / 1-Undecene, Stoich
Coef. = 1

FLOWSHEET: Main
FLUID PACKAGE: Basis-1
STREAM: 1 (Material Stream)
Temperature = 25 C
Pressure = 11.6 bar
Molar Flow = 74.57 kgmole/h
Composition Basis (In Mole Flows): Propane = 3.55761458 / Propene = 71.0123854 / i-
Butane = 0 / n-Butane = 0 / i-Butene = 0 / 1-Butene = 0 / 1-Hexene = 0 / 1-Heptene = 0 / 1-
Octene = 0 / 1-Undecene = 0 /
STREAM: 2 (Material Stream)
Temperature = 25 C
Pressure = 3 bar
Molar Flow = 163.21 kgmole/h
Composition Basis (In Mole Flows): Propane = 0 / Propene = 0 / i-Butane = 29.44 / n-Butane
= 34.41 / i-Butene = 8.27 / 1-Butene = 90.95 / 1-Hexene = 0.14 / 1-Heptene = 0 / 1-Octene = 0
/ 1-Undecene = 0 /
UNIT OPERATION: MIX-101 (Mixer)
Feed Stream = 1a
Feed Stream = 2b
Product Stream = 3
Pressure Specification=Set to lowest inlet

Page | 17
UNIT OPERATION: P-1201 A/B (Pump)
Feed Stream = 2
Product Stream = 2a
Energy Stream = P-1201-Q
DeltaP = 603 kPa
AdiabaticEfficiency = 40 %
STREAM: 2a (Material Stream)
Temperature = 25 C
STREAM: P-1201-Q (Energy Stream)
Heat Flow = 24300 kJ/h
UNIT OPERATION: E-1202 (Heater)
Feed Stream = 4
Product Stream = 4b
Energy Stream = E-1202-Q
Pressure Drop = 0 kPa
Heat Flow = 3827000 kJ/h
UNIT OPERATION: T-1201 (Shortcut Column)
Feed Stream = 4d
OverHead Stream = 6a
Bottoms Stream = 8
Condenser Energy Stream = E-1204-Q
Reboiler Energy Stream = E-1203-Q
CondenserPressure = 5.5 bar
ReboilerPressure = 5.8 bar
ExternalReflux = 0.553112924
LightKeySpec = 0.007673
HeavyKeySpec = 0.0018
LightKeyIndex = 5
HeavyKeyIndex = 6
UNIT OPERATION: R-1201 (Conversion Reactor)
Feed Stream = 3
Vapour Product = 4v
Liquid Product = 4a
Reaction Set=Set-2
ActLikeSeparator = False
PercentLiquidLevel = 100 %
Diameter = 3 m
Height = 13 m
SinglePhase = 1
ReactionName = Rxn-2
ReactionName = Rxn-4
ReactionName = Rxn-6
ReactionName = Rxn-7
UNIT OPERATION: VLV-100 (Valve)
Feed Stream = 1
Product Stream = 1a

Page | 18
 Pressure Drop = 100 kPa
UNIT OPERATION: VLV-101 (Valve)
Feed Stream = 2a
Product Stream = 2b
Pressure Drop = 100 kPa
UNIT OPERATION: E-1201 (Cooler)
Feed Stream = 4v
Product Stream = 4va
Energy Stream = E-1201-Q
Pressure Drop = 30 kPa
Heat Flow = 4230000 kJ/h
STREAM: E-1201-Q (Energy Stream)
Heat Flow = 4230000 kJ/h
Utility Type= Refrigerant 1
UNIT OPERATION: MIX-100 (Mixer)
Feed Stream = 4va
Feed Stream = 4a
Product Stream = 4
UNIT OPERATION: VLV-102 (Valve)
Feed Stream = 4b
Product Stream = 4c
Pressure Drop = 190 kPa
STREAM: E-1202-Q (Energy Stream)
Heat Flow = 3827000 kJ/h
Utility Type= LP Steam
UNIT OPERATION: X-1201 (Component Splitter)
Feed Stream = 4c
Energy Stream = X-1201-Q
OverHead Stream = 7a
Bottoms Stream = 4d
StreamSpecifications = 0
PressureOption = 0
StreamName = 7a
ComponentName = Propane
FractionToOverhead = 0.843
ComponentName = Propene
FractionToOverhead = 1
ComponentName = i-Butane
FractionToOverhead = 0
ComponentName = n-Butane
FractionToOverhead = 0
ComponentName = i-Butene
FractionToOverhead = 0
ComponentName = 1-Butene
FractionToOverhead = 0
ComponentName = 1-Hexene

Page | 19
 FractionToOverhead = 0
ComponentName = 1-Heptene
FractionToOverhead = 0
ComponentName = 1-Octene
FractionToOverhead = 0
ComponentName = 1-Undecene
FractionToOverhead = 0
STREAM: 7a (Material Stream)
Vapour Fraction = 1
Pressure = 5.5 bar
STREAM: 4d (Material Stream)
Vapour Fraction = 0
Pressure = 5.8 bar
UNIT OPERATION: VLV-103 (Valve)
Feed Stream = 7a
Product Stream = 7
Pressure Drop = 50 kPa
ResistanceType = 2
UNIT OPERATION: P-1203 (Pump)
Feed Stream = 6a
Product Stream = 6b
Energy Stream = P-1023-Q
DeltaP = 205 kPa
AdiabaticEfficiency = 40 %
PumpDeltaPSpecActive = 1
UNIT OPERATION: VLV-104 (Valve)
Feed Stream = 6b
Product Stream = 6
Pressure Drop = 100 kPa
UNIT OPERATION: VLV-105 (Valve)
Feed Stream = 8
Product Stream = 8a
Pressure Drop = 100 kPa
UNIT OPERATION: T-1202 (Shortcut Column)
Feed Stream = 8a
OverHead Stream = 10a
Bottoms Stream = 11
Condenser Energy Stream = E-1206-Q
Reboiler Energy Stream = E-1205-Q
CondenserPressure = 2 bar
ReboilerPressure = 2.5 bar
ExternalReflux = 3.11229947
LightKeySpec = 0.005797902
HeavyKeySpec = 0.012032086
LightKeyIndex = 6
HeavyKeyIndex = 7

Page | 20
UNIT OPERATION: P-1205 (Pump)
Feed Stream = 10a
Product Stream = 10
Energy Stream = P-1205-Q
DeltaP = 247 kPa
AdiabaticEfficiency = 40 %
UNIT OPERATION: VLV-106 (Valve)
Feed Stream = 10
Product Stream = 10b
Pressure Drop = 280 kPa
UNIT OPERATION: E-1207 (Cooler)
Feed Stream = 10b
Product Stream = Hexenes
Energy Stream = E-1207-Q
Pressure Drop = 0 kPa
Heat Flow = 146000 kJ/h
STREAM: E-1207-Q (Energy Stream)
Heat Flow = 146000 kJ/h
UNIT OPERATION: P-1204 (Pump)
Feed Stream = 11
Product Stream = 11a
Energy Stream = P-1204-Q
DeltaP = 250 kPa
AdiabaticEfficiency = 40 %
UNIT OPERATION: VLV-107 (Valve)
Feed Stream = 11a
Product Stream = 11b
Pressure Drop = 100 kPa
UNIT OPERATION: T-1203 (Shortcut Column)
Feed Stream = 11b
OverHead Stream = 13a
Bottoms Stream = 14
Condenser Energy Stream = E-1209-Q
Reboiler Energy Stream = E-1208-Q
CondenserPressure = 1.5 bar
ReboilerPressure = 2 bar
ExternalReflux = 1.69953416
LightKeySpec = 0.075525813
HeavyKeySpec = 0.00310559
LightKeyIndex = 7
HeavyKeyIndex = 8
UNIT OPERATION: VLV-108 (Valve)
Feed Stream = 14
Product Stream = 14a
Pressure Drop = 30 kPa
UNIT OPERATION: E-1211 (Cooler)

Page | 21
 Feed Stream = 14a
Product Stream = C8+Heavies
Energy Stream = E-1211-Q
Pressure Drop = 0 kPa
Heat Flow = 330000 kJ/h
UNIT OPERATION: P-1206 (Pump)
Feed Stream = 13a
Product Stream = 13
Energy Stream = P-1206-Q
DeltaP = 250 kPa
AdiabaticEfficiency = 40 %
UNIT OPERATION: VLV-109 (Valve)
Feed Stream = 13
Product Stream = 13b
Pressure Drop = 280 kPa
UNIT OPERATION: E-1210 (Cooler)
Feed Stream = 13b
Product Stream = Heptenes
Energy Stream = E-1210-Q
Pressure Drop = 0 kPa
Heat Flow = 372000 kJ/h
STREAM: E-1210-Q (Energy Stream)
Heat Flow = 372000 kJ/h
STREAM: E-1211-Q (Energy Stream)
Heat Flow = 330000 kJ/h

Page | 22