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Cyclohexane Production Unit

Cyclohexane Production Unit. Presented by Brian Clifton. Executive Summary. The cyclohexane production plant is not economically feasible unless the price of cyclohexane is more than double the price of benzene.

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Cyclohexane Production Unit

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  1. Cyclohexane Production Unit Presented by Brian Clifton

  2. Executive Summary • The cyclohexane production plant is not economically feasible unless the price of cyclohexane is more than double the price of benzene. • Yellow does not recommend IRI to proceed with the plans to build and operate this facility.

  3. Outline • Process Overview • Economic and Risk Analysis • Pipe Network • Pump System • Heat Exchanger • Distillation Column

  4. Process Overview • Benzene is hydrogenated in a Gibbs reactor at high temperature and pressure to form cyclohexane

  5. Process Overview

  6. Economic Analysis

  7. Economic Analysis • Production Cost: $7.14/gal • Revenue: $3.60/gal • TCI: $2.5 million • NPW: negative $1 billion • Accuracy: ±10% • Required ROI: 8%

  8. Strauss Plots/Propagation of Error • Strauss plots for FCI, product cost, and product cost • Propagation of error method

  9. Monte Carlo Simulation

  10. Piping System • Piping materials made of stainless steel • Insulation thickness of 1 inch • Schedule 40 pipes increased to schedule 80 to operate under bursting strength • FCI of $900,000 for piping system

  11. Piping Specifications

  12. Pumping Section • Cyclohexane is pumped from the process to a storage tank at 555 psia which is 35 feet above the flash tank

  13. Pumping Section

  14. Pump Section • Piping • All pipe are stainless steel schedule 40 • ability to resist corrosion

  15. Pump Section • Pump • Positive displacement pump • 9 hp required • 415 ft head available • All components are stainless steel

  16. Pumping Section • Cost for installation of the pumping section, including the pump, pipes, and valves, was determined to be $105,000 • Total fixed capital investment for the cyclohexane plant up to $2.4 million.

  17. Heat Exchanger Network • There are three heat exchangers in the cylcohexane plant • The heating utility required by the plant is minimized by using the hot product stream to pre-heat the incoming reactant stream.

  18. Heat Exchanger Network • Heat exchanger 1 was designed rigorously • A temperature – heat diagram was created

  19. Heat Exchanger: Design

  20. Heat Exchanger: Design • The single pass, countercurrent design was selected • No baffles were used, in order to maintain the shell-side pressure drop under 5 psi

  21. Heat Exchanger: Design

  22. Heat Exchanger Design • Triangular pitch • Stainless steel heat exchangers • Hot streams were maintained tube side in all heat exchangers • Heat exchanger 2 uses steam to heat the reactant stream • Heat exchanger 3 uses cooling water to cool the product stream

  23. Distillation Column • 30 theoretical trays • Optimal feed location: 16th tray • Column height: 32 feet • Column diameter: 42 inches

  24. Distillation Column • Valve trays • 94 valves / tray • Tray spacing: 24 inches • Condenser heat duty: -1.9 MM Btu/hr • Reboiler heat duty: 3.01 MM Btu/hr

  25. Summary • After the detailed designs were conducted, the cyclohexane plant was shown to not meet IRI’s criteria for profitablity. • Yellow does not recommend IRI building and operating this facility.

  26. Questions ?

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