King Faisal University

College of Engineering
Department of Chemical Engineering
ChE 410 Computer Aided Process Design Lab.

Report 4: Design of Cyclohexane

Production Plant

By:

Mohammed Alqahtani
220014774
Abdullah Alkhaldi
220007771
Abdulhamid Almulhim
221431979
Instructor: Dr. Safdar Hussain
Table of Contents
1. Introduction..............................................................................................................................3
1. Process background.................................................................................................................3
2. Process Specifications.............................................................................................................5
3. Solution and Design of the Plant.............................................................................................6
4. Conclusion.............................................................................................................................12
5. References..............................................................................................................................12

List of Figures
Figure 1 Plant for production ofcyclohexane via benzene hydrogenation.....................................3
Figure 2 Specification for the design of the plant............................................................................4

Figure 3 Overall Layout of the Plant 5

Figure 4 Feed and Mixing Point Worksheet...............................................................................................
Figure 5 Worksheet of the Preheater to the Reactor...................................................................................
Figure 6 Worksheet of the Reactor Unit.....................................................................................................
Figure 7 Worksheet of the Cooler...............................................................................................................
Figure 8 Worksheet of the Flash Drum Unit...............................................................................................
Figure 9 Worksheet and Flowrates at 1st Splitter........................................................................................
Figure 10 Worksheet and Flowrates at the 2nd Splitter................................................................................
Figure 11 Design Parameters of the Distillation Column...........................................................................
Figure 12 Worksheet of the Distillation Column (Comditions)................................................................
Figure 13 Worksheet of the Distillation Column (Compositions)............................................................

List of Tables
Table 1 Equipment IDs and their types...........................................................................................6
 1. Introduction
Cyclohexane is a key compound in the chemical industry, mainly utilized as a precursor for the
synthesis of nylon through intermediates like adipic acid and caprolactam. It is also used as a
solvent in chemical processes. Cyclohexane production is indispensable as it is highly demanded
in polymer production and as an industrial bulk chemical.
One industrial application of benzene by hydrogenation is the production of cyclohexane:
benzene + H2 with a nickel or platinum catalyst, as represented in this reaction:

C₆H₆ + 3H₂ → C₆H₁₂

Under high pressures and temperature, this Exothermic reaction is accomplished well and gives
to high yield and converting Efficiency. This reaction decreases the aromaticity of benzene and
provides a saturated hydrocarbon (cyclohexane) with high chemical stability which is defined as
a key step in cyclohexane production

2. Process background
Construct a Unisim simulation to model the production of cyclohexane via benzene
hydrogenation. The simplified flowsheet for this process is shown below. Fresh benzene and
hydrogen feed streams are first fed through a heater to bring the streams up to reactor feed
temperature and pressure conditions. This feed mixture is then sent to a fixed-bed catalytic
reactor where 3 hydrogen molecules react with 1 benzene molecule to form cyclohexane. This
simulation will use a conversion reactor block to model this reaction. The reactor effluent stream
is then sent to a flash tank to separate the light and heavy components of the mixture. The vapor
stream coming off the flash tank is recycled back to the feed mixture after a small purge stream
is removed to prevent impurities from building up in the system. The majority of the liquid
stream leaving the flash tank goes to a distillation column to purify the cyclohexane product,
while a small portion of the liquid stream is recycled back to the feed mixture to minimize losses
of benzene. Process operating specifications are listed on the following page.
3. Process Specifications

Figure 2 Specification for the design of the plant

 4. Solution and Design of the Plant
Benzene and hydrogen are mixed and heated in pre-heater E-100 to 300°F before entering the
reactor unit CRV-100, where they react to form cyclohexane. The reactor effluent is then cooled
to 120°F and sent to the flash drum V-100 for to flash the mixture into a vapor and liquid stream.
The vapor stream from the flash drum is split using TEE-100, with one portion purged to remove
impurities and the other recycled back to the mixer. The liquid stream is divided by splitter TEE-
101, sending one portion to the distillation unit T-100, where cyclohexane is collected as the
bottom product and off-gases are purged from the top. The remaining splitted liquid portion is
recycled back into the system.

Figure 3 Overall Layout of the Plant

Table 1 Equipment IDs and their types

Equipment ID Type
MIX-100 Mixer
E-100 Heater
CRV-100 Conversion Reactor
E-101 Cooler
V-100 Flash Drum
TEE-100 Splitter
TEE-101 Splitter
T-100 Distillation Column

5
 Figure 4 Feed and Mixing Point Worksheet

Figure 5 Worksheet of the Preheater to the Reactor

6
Figure 6 Worksheet of the Reactor Unit

Figure 7 Worksheet of the Cooler

7
 Figure 3 Worksheet of the Flash Drum Unit

Figure 4 Worksheet and Flowrates at 1st Splitter

8
 Figure 5 Worksheet and Flowrates at the 2nd Splitter

Figure 6 Design Parameters of the Distillation Column

9
 Figure 7 Worksheet of the Distillation Column (Comditions)

Figure 8 Worksheet of the Distillation Column (Compositions)

5. Conclusion
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UniSim simulation successfully models the design of cyclohexane production plant which
demonstrates an expressional and efficient workflow. It is initiated by mixing the benzene with
hydrogen, preheating it to the temperature of 300°F in heater E-100 before it enters catalytic
reactor CRV-100. The reactor uses 99.8% of conversion (this is only possible with benzene) to
transform benzene into cyclohexane. The reactor effluent is cooled in E-101 to 120°F and sent to
flash drum V-100 for phase separation.
The vapor stream proceeding from the flash drum is treated by means of an additional splitter
TEE-100 with resultant streams: purge stream to remove impurities and a recycle stream to
enhance feed utilization. The major portion of the liquid stream is sent to the distillation column
T-100, while the minor portion is split by TEE-101. This column separates cyclohexane as
bottom product with 99.99 mole% purity and off-gases as overhead stream.

6. References
Ullmann's Encyclopedia of Industrial Chemistry (2022). "Cyclohexane." Wiley-VCH Verlag
GmbH & Co. KGaA.
Weissermel, K., & Arpe, H.-J. (2012). Industrial Organic Chemistry: Important Raw Materials
and Intermediates. Wiley-VCH.

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