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

Question:

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

Problem 7.23

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

Styrene plant described in Appendix B, Project B.3 B.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

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5th Edition

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

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