epoh inc. consultants: hope baumgarner tyler gibson wes hudkins joseph nick josh stephens
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ePOH Inc.
Consultants:Hope Baumgarner
Tyler GibsonWes HudkinsJoseph Nick
Josh Stephens
ePOH Inc. Addition of a Cylcohexane Production Process
to Independent Refineries Inc.
Overview:
• Based on our findings for project 3, the addition of the cyclohexane unit is not profitable
• Large price increase in cyclohexane would be required to make process profitable
• Current market value Cyclohexane: $4.10/gal
• For process to be profitable price would have to be 5 times the current market value
Project 3
ePOH Inc. Addition of a Cylcohexane Production Process
to Independent Refineries Inc
Economic Analysis:
• Total Capital Investment: TCI = FCI + WC =$4,690,000
• Fixed Capital Investment: FCI = DC + IC = $3,640,000
•Annual Product Cost: $243 MM to $357 MM when a 4% inflation rate is taken into account
•Process considered profitable when ROR > 8%
•Annual Cash Flow: CF = (S-C) x (1-Φ)+dΦ
Project 3
ePOH Inc. Addition of a Cylcohexane Production Process
to Independent Refineries Inc
Economic Analysis:
•Annual Cash Flow:
Price of Cyclohexane Annual Cash Flow
$2.05 ($ 1.29 Billion)
$4.10 ($608 MM)
$20.50 $4.82 Billion
Project 3
ePOH Inc. Addition of a Cylcohexane Production Process
to Independent Refineries Inc
Economic Analysis:
•Net Present Worth: Criterion used to determine profitability
•Payout Time: Time required to recover investment• Positive values indicate that investment will be
recovered • Negative values indicate investment will not be
recovered
•Return on Investment: Describes how much money is earned per dollar invested
• When ROI>ROR the process is profitable
Project 3
ePOH Inc. Addition of a Cylcohexane Production Process
to Independent Refineries Inc
Economic Analysis:
Selling Price Cyclohexane
POT ($/yr) ROI (%) NPW
$2.05 ($0.02) (22.4) ($846 MM)
$4.10 ($0.05) (10.7) ($402 MM)
$20.50 $0.01 83.4 ($3.15 Billion)
Project 3
ePOH Inc. Addition of a Cylcohexane Production Process
to Independent Refineries Inc
Equipment Cost & Specifications
• Mixer & Splitter: • Diameter = 4.9 ft• Height = 19.6 ft• Volume = 185 ft3
• Material: Carbon Steel
• Cost included in the piping cost• Heat Exchangers:
• Shell & Tube • Carbon Steel tubes and shell
Project 3
ePOH Inc. Addition of a Cylcohexane Production Process
to Independent Refineries Inc
Equipment Cost & Specifications:
Heat Exchanger 1 Heat Exchanger 2 Heat Exchanger 3
Fluids Light organics/light
organics
Steam/ light organics
Steam/medium organics
UA (BTU/hr-m2-°F) 88,900 19,550 61,300
Design Value, U (BTU/hr-°F)
660 1040 850
Surface Area (m2) 134 19 72
Cost $18,000 $2,200 $8,000
Project 3
ePOH Inc. Addition of a Cylcohexane Production Process
to Independent Refineries Inc
Equipment Cost & Specifications:
Flash Tank: • Vertical liquid gas gravity settling separator
• Cross sectional area: 57 ft2
• Tank Diameter: 9 ft
• Cost: $81,000
Project 3
ePOH Inc. Addition of a Cylcohexane Production Process
to Independent Refineries Inc
Equipment Cost & Specifications:
Reactor: • Tubular reactor• 30 tubes
• L= 20 ft• OD = 3 inches
• 40% of the cross sectional area dedicated to tubes• Cost: $9,000
Compressor: • Power Requirement: 53 kW• Adiabatic Efficiency: 80%• Type: Centrifugal• Cost: $80,000Project 3
ePOH Inc. Addition of a Cylcohexane Production Process
to Independent Refineries Inc
Equipment Cost & Specifications:
Distillation Column, Condenser & Reboiler:
• Size based on estimated superficial velocity for flooding to occur
• Operation 80% of vapor speed
• Based on Perry’s Chemical Engineer’s Handbook it suggest that about 15% of total cross sectional area be devoted to downcomer envelope
• Number of Trays: 28
• Reboiler: Specified as a kettleProject 3
ePOH Inc. Addition of a Cylcohexane Production Process
to Independent Refineries Inc
Equipment Cost & Specifications:
Distillation Column, Condenser & Reboiler: • Column Cost: $140,000
• Condenser Cost: $40,300
•Reboiler Cost: $515,600
• Total Cost: $781,400
Project 3
ePOH Inc. Fluid Transport and Economic Analysis
• Design of the pipe network• Stainless Steel• Currently operating at unsafe pressures
• Pipes need to be increased to schedule 80• Piping dimensions proposed by IRI found to be less
than optimal• ePOH’s recommendations could save $500,000
• Adding fiberglass insulation will decrease NPW by $1 million
Optimal piping costs for cyclohexane production plant
Piping w/ Insulation $764,120
Valves $65,000
Elbows $4,000
Installation $366,350
Total $1,200,000 Project 4
ePOH Inc. Fluid Transport and Economic Analysis
Two-phase flow
• Pro II was used to determine what flow regimes are inside the two-phase flow pipes in the process
• The Reynolds number was calculated for single phase flow from the thermodynamic parameters given by Pro II, and then the flow regimes for the two-phase streams were taken from the simulation report
• All the single-phase streams are in the turbulent flow regime, and all the two-phase flow streams are in the stratified wavy flow regime
Stream Re Flow Regime
Hydrogen 317000 single-phase turbulent
Benzene 95300 single-phase turbulent
Recycle 605000 single-phase turbulent
Feed 59800 single-phase turbulent
Top 215000 stratified wavy
Bottom 72500 single-phase turbulent
Purge 202000 stratified wavy
S1 2800000 stratified wavy
S2 2480000 stratified wavy
S3 2350000 single-phase turbulent
S4 2140000 single-phase turbulent
S5 83200 stratified wavy
S6 46900 stratified wavy
S7 11800 stratified wavy
S8 9450 stratified wavy
Project 4
ePOH Inc. Fluid Transport and Economic Analysis
Pressure Drop in Streams
• Pressure drops in the pipes are much smaller than the overall pressure gradient in the system
• Current compressor pushes the stream up to 500 psia while they exit the system at atmospheric pressure
• There is no need to add additional pumps and compressors to overcome the pressure drop in the pipes
Stream Type Length (ft) ΔP (psi)
Hydrogen 8’’ Sch 40 700 0.0059
Benzene 4’’ Sch 40 500 0.89
Recycle 8’’ Sch 40 350 0.0062
Feed 6’’ Sch 40 150 0.102
Top 8’’ Sch 40 500 0.00018
Bottom 6’’ Sch 40 500 0.129
Purge 6’’ Sch 40 300 0.00139
S1 10’’ Sch 40 150 0.0165
S2 10’’ Sch 40 100 0.0148
S3 10’’ Sch 40 150 0.0278
S4 10’’ Sch 40 150 0.0229
S5 10’’ Sch 40 100 0.0195
S6 10’’ Sch 40 150 0.0413
S7 10’’ Sch 40 150 0.0027
S8 10’’ Sch 40 100 0.00291
Project 4
ePOH Inc. Fluid Transport and Economic Analysis
• Performed risk analysis on the cyclohexane unit• High risk, very low return• Less than 20% chance of breaking even• The difference between cyclohexane (product) and
benzene (raw material) would need to increase to $1.51/gallon
• ePOH does NOT recommend constructing the cylcohexane unit• Could use Diels Alder reaction as an alternative way to
produce cylcohexane
H2, Pt
Project 4
ePOH Inc.
NPSHA vs. Flow Rate
0 200 400 600 800 1000 1200 14001380
1390
1400
1410
1420
1430
1440
1450
1460
1470
1480
Flowrate (ft3/hr)
NPS
HA
(ft)
Project 5
ePOH Inc.
System Head vs. Flow Rate
0 200 400 600 800 1000 1200 14000
50
100
150
200
250
Flow Rate (ft3/hr)
Syst
em H
ead
(ft)
Project 5
ePOH Inc.
Pumping section PFD
Project 5
ePOH Inc.
Reactor Specifications
Reactor Material Chosen: Type 304 Stainless Steel
Advantages of material:
• resist to corrosion
• high alloy metal
• very high tensile strength
Project 5
ePOH Inc.
Piping and Insulation Specifications
Piping Insulation
Material selected
Type 304 stainless steel Fiberglass
(chosen to resist corrosion)
(low thermal conductivity)
Thickness n/a 1-2.5 in.
Bursting Strength
62,000 kPa n/a
Cost $1,800 ---
Project 5
ePOH Inc.
Pump Specifications
P u m p
Centrifugal pump - chosen due to its low cost and ease of maintenance
Work needed 5.98 Hp
Pressure gain 117.7 psi
Head 360.5 ft
Cost ~ $3,000
Project 5
ePOH Inc.
Pumping Section: Fixed Capital Investment
Centrifugal Pump Cost $3,000
Piping Cost $1,800
Total Material Cost $4,800
Installation Cost $2,250
Total Cost (2002) $7,050
Total Cost (2009) $7,500
Project 5
CH-Plant: Heat Exchanger StudyePOH Inc.
M1 E1
E2
F1
SP1
C1
R1
E3
BENZENE
HYDROGEN
S3
S5
S4
S6
S7
S9 S10
S11
S12
S13
S1
500 psig
Eff. 80%
Purge Gas
Product
DP=15 psi
300 F
120 F
Recycle
E2
E1
E3
Project 6
ePOH Inc.
Heat Exchanger: Hand Design
•Exchanger E1 designed for two cases: Single-Pass Tubes Double-Pass Tubes
•Equipment cost determined for each design
•T-Q Diagram compared
Project 6
ePOH Inc.
Outer Diameter of Tubes (ft) 0.75
Length of Tubes (ft) 12
Pitch (Square) (ft) 0.08
Number of Tubes 500
Area (ft2) 1,165
Shell Diameter (ft) 2.12
Heat Transfer Coefficient (Shell Side)
(Btu/hr-ft2-F)
15.2
Heat Transfer Coefficient (Tube Side)
(Btu/hr-ft2-F)
1.40
Outer Diameter of Tubes (ft) 0.75
Length of Tubes (ft) 12
Pitch (Square) (ft) 0.08
Number of Tubes 920
Area (ft2) 2,160
Shell Diameter (ft) 2.80
Heat Transfer Coefficient (Shell Side)
(Btu/hr-ft2-F)
55.3
Heat Transfer Coefficient (Tube Side)
(Btu/hr-ft2-F)
1.38
Single-Pass Tubes Double-Pass Tubes
Project 6
ePOH Inc.
T-Q Diagrams: E1 Single-Pass Tubes Double-Pass Tubes
0 1 2 3 4 5 6 7 8 9 100
50
100
150
200
250
300
350
400
450
500
0
50
100
150
200
250
300
350
400
450
500
T-Q Diagram
Cold Stream
Hot Stream
Q (MMBTU/hr)
Tem
pera
ture
(°F)
0 1 2 3 4 5 6 7 8 9 100
50
100
150
200
250
300
350
400
450
500
0
50
100
150
200
250
300
350
400
450
500
T-Q Diagram
Cold Stream
Hot Stream
Q (MMBTU/hr)
Tem
pera
ture
(°F)
Project 6
ePOH Inc.
Heat Exchanger: Rigorous Model•Rigorous heat exchanger model used for exchanger E1•Tube length and diameter and shell diameter were varied to produce the smallest heat transfer area•Designed using Pro II Process Simulator
* Minimize heat transfer area to Minimize cost!
Project 6
ePOH Inc.
Heat Exchanger: Rigorous Model
Square Pitch236 tubes, each 16 feet long1275 ft2 heat transfer area11,600,000 Btu/hr heat duty
Project 6
ePOH Inc.
Heat Exchanger 2 and 3
Designed using the simple heat exchanger models with Pro II
Project 6
ePOH Inc.
Cost of Heat Exchangers
Number
Exchangers
Purchased
Cost /
Exchanger
Total Purchased
Cost (2002)
Total Purchased Cost
(2008)
3 $30,830 $92,490 $133,160
Purchased Cost of all
exchangers$133,160
Total FCI of all
exchangers$388,830
Project 6
ePOH Inc.
Cyclohexane Tower Dimensions7 feet in diameter, 56 feet tall28 trays inside column2 foot spacing between columnCondenser duty: -3,300 Btu/secReboiler duty: 3,700 Btu/sec
• Column sized assuming vapor velocity is 80% of that required for flooding from the following correlation:
Project 6