ChE 455

Fall 2010
Major 1

Styrene Production
Styrene is the monomer used to make polystyrene, which has a multitude of uses, the most
common of which are in packaging and insulated, styrofoam beverage cups. Styrene is produced
by the dehydrogenation of ethylbenzene. Ethylbenzene is formed by reacting ethylene and
benzene, and one of the ways benzene is made is by the hydrodealkylation or transalkylation of
toluene, which is obtained as a byproduct of gasoline manufacture. There is very little
ethylbenzene sold commercially. Most ethylbenzene manufacturers convert it directly into
styrene in the same plant.

The plant at which you are employed currently manufactures ethylbenzene and styrene. This
plant was recently acquired by your company in a takeover, and a team of engineers has been
assigned to solve the problems observed in the process over the last few years. The unit to which
you are assigned, Unit 400, converts the ethylbenzene into styrene, producing around 100,000
metric tons per year of 99.8 wt % styrene.

Process Description

The process flow diagram is shown in Figure 1. The reactions, the kinetics, and the
equilibrium equations are detailed in Appendix 1. Ethylbenzene feed is mixed with recycled
ethylbenzene, heated, and then mixed with high-temperature, superheated steam. Steam is an
inert in the reaction, which drives the equilibrium (shown in Equation 1 in the Appendix 1) to the
right by reducing the concentrations of all components. Since styrene formation is highly
endothermic, the superheated steam also provides energy to drive the reaction to the right. The
reactants then enter two adiabatic packed beds with interheating. The products are cooled,
producing steam from the high-temperature reactor effluent. The cooled product stream is sent
to a three-phase separator, in which light gases (hydrogen, methane, ethylene), organic liquid,
and water each exit in separate streams. The hydrogen stream is further purified as a source of
hydrogen elsewhere in the plant. The small amount of benzene and toluene is distilled and either
incinerated for its fuel value or returned to the ethylbenzene process (since the benzene raw
material always has some toluene impurity). The ethylbenzene and styrene stream is distilled to
separate unreacted ethylbenzene for recycle from the styrene product.

The styrene product can spontaneously polymerize at higher temperatures. Since our product
styrene is sent directly to the polymerization unit, experience suggests that as long its
temperature is maintained below 125°C, there is no spontaneous polymerization problem. Since
this is below styrene’s normal boiling point, and since low pressure pushes the equilibrium to the
right, much of this process is run at low pressures, with much of the separation section at
vacuum.

Tables 1 and 2 show the design conditions for Unit 400. Table 3 contains an equipment list.
Other pertinent information and calculations are contained in Appendix 2.
2
 Table 1
Stream Tables for Unit 400

Stream No. 1 2 3 4 5
Temperature (°C) 136.00 116.04 240.00 253.79 800.00
Pressure (kPa) 200.00 190.00 170.00 4237.00 4202.00
Vapor Mole Fraction 0.00 0.00 1.00 1.00 1.00
Total Flow (kg/h) 13,052.22 23,965.10 23,965.10 72,353.71 72,353.71
Total Flow (kmol/h) 123.42 226.21 226.21 4016.30 4016.30
Component Flows
Water 0.00 0.00 0.00 4016.30 4016.30
Ethylbenzene 121.00 223.73 223.73 0.00 0.00
Styrene 0.00 0.06 0.06 0.00 0.00
Hydrogen 0.00 0.00 0.00 0.00 0.00
Benzene 1.21 1.21 1.21 0.00 0.00
Toluene 1.21 1.21 1.21 0.00 0.00
Ethylene 0.00 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00 0.00

Stream No. 6 7 8 9 10
Temperature (°C) 722.03 566.57 504.27 550.00 530.07
Pressure (kPa) 170.00 160.00 150.00 135.00 125.00
Vapor Mole Fraction 1.00 1.00 1.00 1.00 1.00
Total Flow (kg/h) 54,045.00 78,010.10 78,010.18 78,010.18 78,010.19
Total Flow (kmol/h) 3000.00 3226.21 3317.28 3317.28 3346.41
Component Flows
Water 3000.00 3000.00 3000.00 3000.00 3000.00
Ethylbenzene 0.00 223.73 132.35 132.35 102.88
Styrene 0.00 0.06 91.06 91.06 120.09
Hydrogen 0.00 0.00 90.69 90.69 119.38
Benzene 0.00 1.21 1.28 1.28 1.37
Toluene 0.00 1.21 1.52 1.52 1.86
Ethylene 0.00 0.00 0.07 0.07 0.16
Methane 0.00 0.00 0.31 0.31 0.65
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Table 1
Stream Tables for Unit 400 (cont’d)

Stream No. 11 12 13 14 15
Temperature (°C) 267.00 180.00 65.00 65.00 65.00
Pressure (kPa) 110.00 95.00 80.00 65.00 65.00
Vapor Mole Fraction 1.00 1.00 0.15 1.00 0.00
Total Flow (kg/h) 78,010.19 78,010.19 78,010.19 255.64 54,045.00
Total Flow (kmol/h) 3346.41 3346.41 3346.41 120.20 3000.00
Component Flows
Water 3000.00 3000.00 3000.00 0.00 3000.00
Ethylbenzene 102.88 102.88 102.88 0.00 0.00
Styrene 120.09 120.09 120.09 0.00 0.00
Hydrogen 119.38 119.38 119.38 119.38 0.00
Benzene 1.37 1.37 1.37 0.00 0.00
Toluene 1.86 1.86 1.86 0.00 0.00
Ethylene 0.16 0.16 0.16 0.16 0.00
Methane 0.65 0.65 0.65 0.65 0.00

Stream No. 16 17 18 19 20
Temperature (°C) 65.00 69.89 125.02 90.83 123.67
Pressure (kPa) 65.00 45.00 65.00 25.00 55.00
Vapor Mole Fraction 0.00 0.00 0.00 0.00 0.00
Total Flow (kg/h) 23,709.57 289.52 23,420.04 10,912.92 12,507.12
Total Flow (kmol/h) 226.21 3.34 222.88 102.79 120.08
Component Flows
Water 0.00 0.00 0.00 0.00 0.00
Ethylbenzene 102.88 0.10 102.78 102.73 0.05
Styrene 120.09 0.00 120.09 0.06 120.03
Hydrogen 0.00 0.00 0.00 0.00 0.00
Benzene 1.37 1.37 0.00 0.00 0.00
Toluene 1.86 1.86 0.00 0.00 0.00
Ethylene 0.00 0.00 0.00 0.00 0.00
Methane 0.00 0.00 0.00 0.00 0.00
 5

Table 1
Stream Tables for Unit 400 (cont’d)

Stream No. 21 22 23 24 25
Temperature (°C) 123.78 65.04 202.21 90.96 800.00
Pressure (kPa) 200.00 200.00 140.00 200.00 4202.00
Vapor Mole Fraction 0.00 0.00 1.00 0.00 1.00
Total Flow (kg/h) 12,507.12 54,045.00 255.64 10,912.92 18,308.71
Total Flow (kmol/h) 120.08 3000.00 120.20 102.79 1016.30
Component Flows
Water 0.00 3000.00 0.00 0.00 1016.30
Ethylbenzene 0.05 0.00 0.00 102.73 0.00
Styrene 120.03 0.00 0.00 0.06 0.00
Hydrogen 0.00 0.00 119.38 0.00 0.00
Benzene 0.00 0.00 0.00 0.00 0.00
Toluene 0.00 0.00 0.00 0.00 0.00
Ethylene 0.00 0.00 0.16 0.00 0.00
Methane 0.00 0.00 0.65 0.00 0.00

Table 2
Utility Summary for Unit 400
(all units of kg/h)

E-401 E-403 E-404 E-405

hps bfw → hps bfw → lps cw
7982 18,451 5562 3,269,746

E-406 E-407 E-408 E-409

cw lps cw lps
309,547 7,550 1,105,980 21,811
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Table 3
Partial Equipment Summary

Heat Exchangers
H-401 E-401
fired heater – refractory-lined, stainless-steel tubes carbon steel
design Q = 23.63 MW A = 260 m2
max Q = 25.00 MW boiling in shell, condensing in tubes
1 shell – 2 tube passes
Q = 13,530 MJ/h
E-402 E-403
316 stainless steel 316 stainless steel
A = 226 m2 A = 1457 m2
steam in shell, process fluid in tubes boiling in shell, process fluid in tubes
1 shell – 2 tube passes 1 shell – 2 tube passes
Q = 8322 MJ/h Q = 44,595 MJ/h
E-404 E-405
carbon steel 316 stainless steel
A = 702 m2 A = 1446 m2
boiling in shell, process fluid in tubes cw in shell, process fluid in tubes
1 shell – 2 tube passes 1 shell – 2 tube passes
Q = 13,269 MJ/h Q = 136,609 MJ/h
E-406 E-407
carbon steel carbon steel
A = 173 m2 A = 64 m2
process fluid in shell, cooling water in tubes boiling in shell, steam condensing in tubes
1 shell – 2 tube passes desuperheater – steam saturated at 150°C
Q = 12,951 MJ/h 1 shell – 2 tube passes
Q = 15,742 MJ/h
E-408 E-409
carbon steel carbon steel
A = 385 m2 A = 176 m2
process fluid in shell, cooling water in tubes boiling in shell, steam condensing in tubes
1 shell – 2 tube passes desuperheater – steam saturated at 150°C
Q = 46,274 MJ/h 1 shell – 2 tube passes
Q = 45,476 MJ/h

Reactors
R-401 R-402
316 stainless steel, packed bed 316 stainless steel, packed bed
cylindrical catalyst pellet (1.6 mm×3.2 mm) cylindrical catalyst pellet (1.6 mm×3.2 mm)
void fraction = 0.4 void fraction = 0.4
V = 25 m3 V = 25 m3
9.26 m tall, 1.85 m diameter 9.26 m tall, 1.85 m diameter
 7

Towers
T-401 T-402
carbon steel carbon steel
D = 3.0 m D = 6.9 m
61 sieve trays 158 bubble cap trays
54% efficient 55% efficient
feed on tray 31 feed on tray 78
12 in tray spacing 6 in tray spacing
1 in weirs 1 in weirs
column height = 61 ft = 18.6 m column height = 79 ft = 24.1 m

Other Equipment
C-401 V-401
carbon steel carbon steel
W = 134 kW V = 26.8 m3
60% adiabatic efficiency
P-401 A/B P-404 A/B
stainless steel carbon steel
W = 2.59 kW (actual) W = 0.775 kW (actual)
80% efficient 80% efficient
P-405 A/B
carbon steel
W = 0.825 kW (actual)
80% efficient

Problem

Your company acquired this plant from another company through a take-over. Previously,
this other company was having many problems meeting specifications and had lost customers
because of these problems. Your company is in the process of diagnosing and fixing these
problems to bring the plant back on-line at full capacity with product that meets specifications.

It is desired to bring the plant back on-line as soon as possible. However, there is a problem
in the steam plant that will take much longer to fix. Therefore, the source of high-pressure steam
that enters the process for which all condensate is not returned (Stream 4) will not be available.
Because of excess capacity, it will be possible to use medium- or low-pressure steam as a
process feed. The questions that must be answered are how this will affect the styrene
production rate and how equipment performance will be affected. This is the primary
assignment.

Additionally, current market conditions for styrene are very tight. Whatever we can do to
improve the economic performance of Unit 400 will help the bottom line. Therefore, the second
part of your assignment is to suggest process improvements that will enhance the profitability of
Unit 400, especially ones that can reasonably be implemented during the upcoming shut down,
such as changing operating conditions rather than purchasing new equipment. The cost and
economic benefit of these suggested changes should be presented. The economic criterion to be
used for analysis of process improvements is 15% before taxes over 7 years.
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Deliverables

Specifically, the following is to be completed by 9:00 a.m., Monday, November 15, 2010:

1. Prepare a written report, conforming to the guidelines, detailing the solution to the problem.

2. Provide a list of suggested process improvements which can enhance the profitability of Unit
400.

3. Submit a written report, conforming to the guidelines, detailing the information in items 1
and 2, above

4. Include an updated PFD and stream table for the modified process.

5. Include a legible, organized set of calculations justifying your recommendations, including

any assumptions made

6. Include a signed copy of the attached confidentiality statement

Report Format

This report should be brief and should conform to the guidelines, which are available at the
end of the following web page: http://www.che.cemr.wvu.edu/publications/projects/index.php.
It should be bound in a 3-ring binder/folder that is not oversized relative to the number of pages
in the report. Figures and tables should be included as appropriate. An appendix must be
attached that includes items such as the requested calculations and a Chemcad consolidated
report (required) of the converged simulation for your recommended case. Stream properties
(viscosity, density, etc.) are not to be included in the Chemcad consolidated report but stream
conditions and components must be included, and there will be a deduction if these rules are not
followed. The calculations in the appendix should be easy to follow. The confidentiality
statement should be the very last page of the report.

The written report is a very important part of the assignment. Reports that do not conform to
the guidelines will receive severe deductions and will have to be rewritten to receive credit.
Poorly written and/or organized written reports may also require re-writing. Be sure to follow
the format outlined in the guidelines for written reports.

Oral Presentation

You will be expected to present and defend your results some time between November 15,
2010 and November 19, 2010. Your presentation should be 15-20 minutes, followed by about a
30-minute question and answer period. Make certain that you prepare for this presentation since
it is an important part of your assignment. You should bring at least one hard copy of your slides
to the presentation and hand it out before beginning the presentation.
 9

Other Rules

You may not discuss this major with anyone other than the instructors. Discussion,
collaboration, or any interaction with anyone other than the instructor is prohibited. This means
that any cross talk among students about anything relating to this assignment, no matter how
insignificant it may seem to you, is a violation of the rules and is considered academic
dishonesty. Violators will be subject to the penalties and procedures outlined in the University
Procedures for Handling Academic Dishonesty Cases (see p. 45 of 2009-11 Undergraduate
Catalog (http://coursecatalog.wvu.edu/fullcatalogs/09-11catalog.pdf) or follow the link
http://www.arc.wvu.edu/rightsa.html).

Consulting is available from the instructors. Chemcad consulting, i.e., questions on how to
use Chemcad, not how to interpret results, is unlimited and free, but only from the instructors.
Each individual may receive five free minutes of consulting from the instructors. After five
minutes of consulting, the rate is 2.5 points deducted for 15 minutes or any fraction of 15
minutes, on a cumulative basis. The initial 15-minute period includes the 5 minutes of free
consulting.

Late Reports

Late reports are unacceptable. The following severe penalties will apply:

• late report on due date before noon: one letter grade (10 points)

• late report after noon on due date: two letter grades (20 points)

• late report one day late: three letter grades (30 points)

• each additional day late: 10 additional points per day

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Appendix 1
Reaction Kinetics and Equilibrium

The reactions for styrene production are as follows:

k1
C 6 H 5C 2 H 5 → C6 H 5C 2 H 3 + H2 (1)
k2
ethylbenzene styrene hydrogen

k3
C6 H 5C 2 H 5 → C6 H 6 + C 2 H 4 (2)
ethylbenzene benzene ethylene

k4
C6 H 5C2 H 5 + H 2 → C6 H 5CH 3 + CH 4 (3)
ethylbenzene hydrogen toluene methane

Kinetics (subscripts on r refer to reactions in Equation (1) – (3) (adapted from Snyder, J. D.
and B. Subramaniam, Chem. Engr. Sci., 49, 5585-5601 (1994) – the positive activation energy
can arise from non-elementary kinetics and/or from reversible reactions:

⎛ 21708 ⎞
r1 = 1.177 × 10 8 exp⎜ − ⎟ p eb (4)
⎝ RT ⎠

⎛ 7804 ⎞
r2 = 20.965 exp⎜ ⎟ p sty p hyd (5)
⎝ RT ⎠

⎛ 49675 ⎞
r3 = 7.206 × 1011 exp⎜ − ⎟ peb (6)
⎝ RT ⎠

⎛ 21857 ⎞
r4 = 1.724 × 106 exp⎜ − ⎟ peb phyd (7)
⎝ RT ⎠

where p is in bar, T is in K, R = 1.987 cal/mol K, and ri is in mol/m3 reactor s. When simulating

this, or any, reactor in Chemcad, the units for the reactor may be set separately from the units for
the rest of the simulation in the “more specifications” tab.

The styrene reaction may be equilibrium limited, and the equilibrium constant is

⎛ ysty yhyd P ⎞
K = ⎜⎜ ⎟⎟ (8)
⎝ yeb ⎠
 11

and
14852.6
ln K = 15.5408 − (9)
T

where T is in K and P is in bar.

other data:

bulk catalyst density = 1282 kg/m3

void fraction = 0.4
 12

Appendix 2
Calculations and Other Pertinent Information

Vessel (V-401)

assume 10 min residence time based on total liquid flow, calculate volume and double it to
provide space for vapor disengagement

organic liquid at 26.6 m3/h

water at 54.0 m3/h
total liquid flow = 80.6 m3/h = 1.34 m3/min
total volume = 26.8 m3

Heat Exchangers

key data:

latent heats
λhps = 1695 kJ/kg
λmps = 2002 kJ/kg
λlps = 2085 kJ/kg

E-401

zone 1
Q1 = 2301.11 MJ/h
ΔTlm = 113.96°C 254
liquid organic h = 600 W/m2K
240
condensing steam h = 6000 W/m2K
U ≈ 1/hi + 1/ho = 545.45 W/m2K
A = 10.29 m2 160 157
117
zone 2
Q2 = 7546.36 MJ/h
ΔTlm = 95.57°C zone 1 zone 2 zone 3
boiling organic h = 5000 W/m2K
condensing steam h = 6000 W/m2K
temperature drop in this zone due to pressure drop
U ≈2727.27 W/m2K
A = 8.04 m2

zone 3
Q3 = 3681.13 MJ/h
ΔTlm = 42.93°C
vapor organic h = 100 W/m2K
condensing steam h = 6000 W/m2K
 13

U ≈ 98.36 W/m2K
A = 242.13 m2

total A = 260.46 m2
steam flowrate from Chemcad in Table 2

E-402
800
Q = 8321.66 MJ/h
ΔTlm = 160.71°C 600
550
hot desuperheating steam h = 200 W/m2K
hot vapor organic h = 100 W/m2K 504
U ≈ 66.67 W/m2K
LMTD corr factor – 1-2 exchanger = 0.9529
A = 226.46 m2

E-403
530
Q = 44,594.43 MJ/h
ΔTlm = 86.09°C 267
boiling water h = 8000 W/m2K
hot vapor organic h = 100 W/m2K 254
U ≈ 98.77 W/m2K 90
A = 1456.85 m2
bfw flowrate from Chemcad in Table 2
267
E-404
180

Q = 13,268.50 MJ/h 159

ΔTlm = 53.13°C 90
boiling water h = 8000 W/m2K
warm vapor organic h = 100 W/m2K
U ≈ 98.77 W/m2K
A = 702.43 m2
m = Q/(2085 + 293) = 5579.97 kg/h (denominator is λ + CpΔT in kJ/kg)
bfw flowrate from Chemcad in Table 2

E-405 180
zone 1 - desuperheating 65 94.8
Q1 = 12,305.74 MJ/h
ΔTlm = 91.37°C 40
vapor organic h = 100 W/m2K 3 9.2
30
cooling water h = 1000 W/m2K
U ≈ 1/hi + 1/ho = 90.91 W/m2K
A = 411.53 m2
 14

zone 2 – partial condensing – treat like cooling is straight line

Q2 = 124,303.29 MJ/h
ΔTlm = 44.49°C
partial condensation organic h = 3000 W/m2K
cooling water h = 1000 W/m2K
U ≈ 750 W/m2K
A = 1034.781 m2

total A = 1446.31
cw flowrate from Chemcad in Table 2

E-406
69.9
Q = 12,951.45 MJ/h
ΔTlm = 34.65°C
40
condensing organic h = 1500 W/m2K
cooling water h = 1000 W/m2K 30
U ≈ 600 W/m2K
A = 173.05 m2
m = Q/[4.184(10)] = 309,547.08 kg/h (denominator is in kJ/kg)

E-407

Q = 15,742.13 MJ/h 150

ΔTlm = 24.98°C
condensing steam h = 6000 W/m2K 125
boiling organic h = 5000 W/m2K
steam desuperheated to 150°C
U ≈ 2727.27 W/m2K
A = 64.19 m2
m = Q/2085 = 7550.18 kg/h (denominator is λ of steam kJ/kg)

E-408

Q = 46,274.20 MJ/h 90.8

ΔTlm = 55.68°C
condensing organic h = 1500 W/m2K 40
cooling water h = 1000 W/m2K 30
U ≈ 600 W/m2K
A = 384.75 m2
m = Q/[4.184(10)] = 1,105,979.92 kg/h (denominator is in kJ/kg)
 15

E-409
150
Q = 45,476.36 MJ/h
ΔTlm = 26.33°C
123.7
steam desuperheated to 150°C
condensing steam h = 6000 W/m2K
boiling organic h = 5000 W/m2K
U ≈ 2727.27 W/m2K
A = 175.92 m2
m = Q/2085 = 21,811.20 kg/h (denominator is CpΔT of water in kJ/kg)

T-401

from Chemcad 33 ideal stages, feed at 17 (one subtracted for condenser)

sieve trays
flooding within reasonable range from Chemcad
D = 3.0 m
tray spacing = 0.305 m (= 12 in)
from O’Connell correlation in Chemicad, 0.54 average overall column efficiency
weir height = (0.051 m)(0.54) = 0.0275 m (= 1.08 in)
⇒ 61 stages (so column about 61 ft tall =18.6m )
feed at 17(61/33) = 31

T-402

from Chemcad 87 ideal stages, feed at 43 (one subtracted for condenser)

bubble cap trays
flooding within reasonable range from Chemcad
D = 6.9 m
tray spacing = 0.1525 m (6 in)
from O’Connell correlation in Chemicad, 0.55 average overall column efficiency
weir height = (0.051 m)(0.55) = 0.028 m (1.1 in)
⇒ 158 stages (so column about 79 ft tall = 24.1 m)
feed at 43(158/87) = 78

H-401

from Chemcad Q = 63544 MJ/h = 17.65 MW

but this heater must also heat steam used in E-402 (Stream 25)
total flow is Stream 4 on PFD
so Q = 17.65[(3000+1016)/3000] = 23.62 MW
designed for Q = 25.00 MW
split between Streams 6 and 25 is controlled by ratio controller, but the ratio can be changed

Information on other equipment is not available.