Estimate the cost of operating labor (C OL ), the cost of utilities (C UT ), and

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Estimate the cost of operating labor (COL), the cost of utilities (CUT), and the cost of manufacturing (COMd) for the styrene process given in Project B.3 of Appendix B. You must do Problem 7.23 in order to estimate COMd.


Problem 7.23

Determine the bare module, total module, and grassroots cost of the following:

Styrene plant described in Appendix B, Project B.3B.3 STYRENE PRODUCTION, UNIT 400 Styrene is the monomer used to make polystyrene, which has a multitude of

B.3.1 Process Description [1, 2] The process flow diagram is shown in Figure B.3.1. Ethylbenzene feed is

a feed stream to the petrochemical facility. The organic stream containing the desired product is distilled

Figure B.3.1

R-401 R-402 E-403 E-404 E-405 V-401 C-401 Styrene Styrene Product Product Product Three- Reactor Reactor

C6H5C2H5 ethylbenzene 1 C6H5C2H3 + H styrene hydrogen (B.3.1) C6H5 C2H5 C6H6+ CH4 benzene ethylene (B.3.2)

The styrene product can spontaneously polymerize at higher temperatures. Because product styrene is sent

Table B.3.1 Stream Tables for Unit 400 Stream Number Temperature 136.0 (C) Pressure (kPa) Vapor mole fraction

Component Flowrates (kmol/h) Water Ethylbenzene 121.00 Styrene Hydrogen Benzene Toluene Ethylene Methane

Vapor mole 1.00 fraction Total flow (kg/h) Water Total flow (kmol/h) Component Flowrates (kmol/h) Styrene


Stream Number Temperature (C) Pressure (kPa) Vapor mole fraction Total flow (kg/h) Water 11 267.0 Styrene

Benzene Toluene Ethylene Methane Stream Number Temperature (C) Pressure (kPa) Vapor mole fraction Total flow

Water Ethylbenzene 102.88 Styrene Hydrogen Benzene Toluene Ethylene Methane Stream Number 0.00 Pressure (kPa)

Total flow (kg/h) Total flow (kmol/h) Component Flowrates (kmol/h) Water 12,507.1 54,045.0 255.6 Styrene

Stream Number Temperature (C) Pressure (kPa) Vapor mole fraction Total flow (kg/h) 26 70.0 200.00 0.00 289.5

Water Ethylbenzene Styrene Hydrogen Benzene Toluene Ethylene Methane 0.00 0.10 0.00 0.00 1.37 1.86 0.00 0.00

Table B.3.2 Utility Summary for Unit 400 E-401 hps 7982 kg/h E-406 CW 309,547 kg/h E-403 bfw to hps 18,451

Table B.3.3 Major Equipment Summary for Unit 400 Compressors and Drives C-401 Carbon steel W = 134 KW 60%

316 stainless steel A = 226 m Boiling in shell, process fluid in tubes 1 shell--2 tube passes Q = 8322 MJ/h

Carbon steel A = 702 m Boiling in shell, process fluid in tubes 1 shell--2 tube passes Q = 13,269 MJ/h E-405

Fired heater-refractory-lined, stainless-steel tubes Design Q = 23.63 MW Maximum Q = 25.00 MW Pumps P-401 A/B

W = 1.33 kW (actual) 80% efficient P-403 A/B Centrifugal/electric drive Carbon steel W = 0.574 kW (actual)

Towers T-401 Carbon steel D = 3.0 m 61 sieve trays 54% efficient Feed on tray 31 12-in tray spacing 1-in

Carbon steel L/D = 3 V = 5 m See Figure B.3.1 and Table B.3.1 for shell-and tube-side pressures.

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Analysis Synthesis And Design Of Chemical Processes

ISBN: 9780134177403

5th Edition

Authors: Richard Turton, Joseph Shaeiwitz, Debangsu Bhattacharyya, Wallace Whiting

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