Transcript Heat and Material Balances and Pump Analysis

Blue-OX Energy
Management
TJ Chancellor
Paul Cole
Sara Habib
Mira Kim
Claudio Ramos
Vicente Rosas
Benzene
Hydrogenation Process
Project 3: Benzene Hydrogenation
Process
Purpose - provide an economic analysis for the benzene
hydrogenation process.
Objectives 
Estimate the total fixed capital investment

Estimate the annual product cost.

Estimate the annual cash flow for the life of the
project.

Report profitability based on ROI, discounted cash
flow, (NPW), and POT.

NPW if products were sold at half or three times the
price of cyclohexane.
Process Flow Diagram
RECYCLE
S4
S3
E2
R1
S7
PURGE
S2
BENZENE
S1
S8
C1
HYDROGEN
M1
E1
F1
SP1
S6
S5
TOP
1
FEED
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
E3
T1
30
BOTTOM
Results
Direct costs
$1,820,500
Indirect costs
$792,000
Fixed-capital investment
$2,612,500
Working capital
$2,350,807
Total capital investment
$4,963,307
Annual Cash Flow
Year
Annual cash flow ($106)
2005
2006
2007
1.91
1.98
2.06
2008
2009
2010
2.14
2.22
2.30
2011
2.39
2012
2013
2014
2.48
2.58
2.68
Annual Total Product Cost
Total variable cost
Total fixed cost
Total product cost
$ 3,369,345
$ 78,375
$ 3,447,720
Plant overhead
$ 344,772
Manufacturing
$ 3,792,492
Total general expenses
Total product cost
$0
$ 3,792,492
Profitability
Price of
Cyclohexane
(per gallon)
ROI
Discounted
Cash Flow
Rate of
Return
$1.91
-8.2%
N/A
-$5.60
million
N/A
0.60
$8.50
million
1.03 years
3.16
$64.90
million
0.19 years
$3.82
$11.46
40.6%
247%
NPW
POT
Recommendations

If market value of cyclohexane falls below
$2.32/gallon the process should be
discontinued.
Hydrogenation Process
Fluid Flow Economics
Purpose







Perform sensitivity analysis for the quantification of
risk
Determine the minimum price difference between the
product and raw material
Select material types for different piping section
Determine pressure drops through the pipe network in
order to determine if more pumps are needed
Perform safety analysis for the suggested pipes
Suggest insulation material and thickness
Estimate the Fixed Capital Investment
Results
Optimized Pipe Network
Stream
Nominal Diameter
Hydrogen
6 in.
Benzene
2 in.
Recycle
6 in.
Feed
3 in.
Top
4 in.
Bottom
3 in.
Purge
3 in.
S1
8 in.
S2
12 in.
S3
12 in.
S3
12 in.
S5
8 in.
S6
8 in.
S7
6 in.
S8
6 in.
Findings
Optimized Pipe Network Insulation Total Cost
Insulation
Thickness
(m)
Fixed Cost
Heating Cost
Total Cost
0.038
$43,571.16
$1,323,251.56
$1,366,822.72
0.051
$57,622.44
$1,064,904.02
$1,122,526.46
Glass Wool
0.076
$81,488.28
$799,028.52
$880,516.80
85% Magnesia
0.038
$20,711.16
$244,682.69
$265,393.85
0.013
$20,177.76
$384,775.76
$404,953.52
0.025
$24,018.24
$214,653.13
$238,671.37
0.038
$30,815.28
$149,718.75
$180,534.03
0.051
$43,571.16
$117,376.36
$160,947.52
Rock Wool
Findings
Optimized Pipe Network Insulation Total Cost
Percentage less than the Non-optimized
Insulation
Thickness
(m)
Fixed Cost
Heating Cost
Total Cost
0.038
24%
12%
13%
0.051
25%
12%
13%
Glass Wool
0.076
24%
11%
13%
85% Magnesia
0.038
17%
12%
13%
0.013
26%
13%
14%
0.025
26%
13%
14%
0.038
19%
12%
14%
0.051
24%
12%
15%
Rock Wool
Results



For Non-optimized pipes the minimum price is
$1.44
For the Optimized pipes network the minimum
price drop 4 cents to $1.40
Pressure Drop around the entire network was
found negligible
Pressure Drops for Each Stream
Stream
Sch 40
Length
Elbows
Valves
press drop
inches
(feet)
90 deg
(globe)
Dr (lb/ft^2)
Hydrogen
8
700
3
3
0.00015
Benzene
4
500
5
3
0.0181
Recycle
8
350
4
1
0.00398
Feed
6
150
6
2
0.06851
Top
8
500
2
2
0.00008
Bottom
6
500
2
2
0.05471
Purge
6
300
2
1
0.00098
S1
10
150
2
1
0.0764
S2
10
100
2
1
0.05847
S3
10
150
4
2
0.01356
S4
10
150
4
2
0.0113
S5
10
100
2
1
0.08596
S6
10
150
4
2
0.06799
S7
10
150
4
0
0.00249
S8
10
100
2
1
0.00169
Recommendations



By using the nominal diameter suggested the
company will save about $200,000 in the capital
investment for the pipes
Blue Ox determine that 2 inches thick rock wool
insulation is the economical optimum
Based on the simulation and calculation the
pressure drop is negligible throughout the pipe
network thus no new pump or compressor is
necessary at this time
Heat and Material
Balances and Pump
Analysis
Heat and Material Balances and
Pump Analysis
Objectives:
solve
heat and material balances for the process from
Project 3
select an appropriate material for the reactor
determine the work needed at the pump for the
pumping section of the process
suggest a pump type
create NPSHA vs. flow rate diagram
system head vs. flow rate diagram
estimate the Fixed Capital Investment for the
pumping section.
Results:
Material Balance
Heat Balance
Material

Stainless Steel
Reactor contains Hydrogen at high T and P
 Resistant to corrosion
 Ensures reactor safety & longevity


Pump
Work Needed: 5.06 kW



Pressure Drop: 38 psia
Discharge Pressure: 593 psia
Type: regenerative pump (turbine pump )
NPSHA and System Head vs. Flow Rate
Fixed Capital Investment for the
pumping section
Heat Transport
Equipment
Objectives




Design heat exchanger E1 by hand (using Excel)
and by simulation (using Pro/II).
Choose materials for construction of the heat
exchangers.
Generate T-Q diagrams for each of the heat
exchangers.
Design a distillation column for the process.
Hand Design






Double pass heat exchanger.
Nominal Tube Size: ½ inch
Tube Length: 16 feet
Total Area: 2117 ft2
Fluid Flow Rate: 4.73 m3/s
Tube Side Pressure Drop: 1.71 psi
Simulator Design






Front End Stationary Head: Channel and
Removable Cover
Shell Type: Double Pass with Longitudinal
Baffle
Rear End Head: U-Tube Bundle
Shell Inside Diameter: 8 inches
Tubes per Shell: 24
Area: 588ft2
Heat Exchanger E1 Zones Analysis
500.0
Hot S ide
Cold S ide
Temperature, F
400.0
300.0
200.0
100.0
0
0
2.0
4.0
6.0
Duty, x 10^6 BTU/hr
8.0
10.0
Heat Exchanger E2 Zones Analysis
250.0
Hot S ide
Cold S ide
Temperature, F
200.0
150.0
100.0
50.0
0
0
1.2
2.4
3.6
Duty, x 10^6 BTU/hr
4.8
6.0
Heat Exchanger E3 Zones Analysis
400.0
Hot S ide
Cold S ide
Temperature, F
360.0
320.0
280.0
240.0
0
0.50
1.00
1.50
Duty, x 10^6 BTU/hr
2.00
2.50
Heat Exchanger Materials


304 Stainless Steel was chosen as the material for
construction.
Stainless steel was chosen because of the
corrosive properties of methane and benzene.
Economics



Price of a single heat exchanger: $12,155
Purchased Equipment (3 heat exchangers):
$36,465
Fixed Capital Investment: $190,530
Distillation Column






28 Trays. 2 feet between trays. 5 feet for the top
and bottom trays.
Column Height: 66 feet
Tray Diameter: 93 inches
Condenser
Reboiler
Reflux Ratio: 24