Problem 4 (Development of PFD and Economic Performance) Processing costs = Equipment costs / Payback time } The hydrodealky lation of side-chain arumalics to non-substituted parents is a major process in + [Cost of utilitics + [Additional enviconmental costs] petrocheurica] processes [for exanple, benzene is the starting raw material for producing a top The economic potential at any stage n is then EPn=EP1{ Processing costs } commodity cbemical like isopropyl benzene (also called cunese) which accouvts for about 8% of the tatal worldwise propylene oonsumption, Cumene is mostly used to produce phenol and For this prooss PFD EP can be detemived as: watone]. EP=EP1,D[ Rxtor cossts/piyhack time ][ cost of sepris } The conversion of toluene to bentene is carried aut via the reaction: -[utilities costs] - [additional environ costs] C6H99CH3+H2C5H6+CH4 You can assume that envirommental costs are 56% of product and by-product sales. It can be at 3050 har, either themally at 550700C, or over a suitable catalyst, Thermally, the conversion assunod also that salesi(all other costs in EP1/0 ) ratio is 1.73.0. Use this information to is 6080% with selectivity =95% [of course, selectivity is higher with catalyst]. Other signilicant side reaction produces diphtenyl via resction: determine anuual EP1/0 after obtaining the sales costs ol products and by-produets [assume 340 2LsH6+C12H10+H2 days of manufecture ner yeas]. Provide a teference of where you bblain up bo current sles cost data. (i) Feeds are introduced by mixiog pure tolueve and bydrogen with 5% methane. Hydrogen is recycled bock to the process hut ta avoid accumulation of methane in process sime purge sirearm of H2 ibethane is added to the process from which valuable mothane is recovered via (g) As you ean fealize, there are a lot of opportunities for energy integration (even stean mesbbanes. generation) for this process. Identify points in the proposed PFD where additions] beat exahangers are located. Compare the PFD ta ane involving a catalytic process (locate in patents) (ii) All toluene is recycled. Bul ratio H2, toluene of 5 is maintained at resctor inlet to avoid C firmation. We will assume reaction takes place at 401 har and temperature of 601C. (iii) Raw feeds will be heated (in fiamnce) before introduction to the plog flow reactor and the reactor outlet products will be oooled befire sending them to a single slage llash uniL A simulation of the llash unit al 41 har \& 305K using Peng-Robinson EOS gives the K values in the table (table includes operatiog data too). (a) Chasin builing points of toluene, dipheriyl and henzene and identify the scheme used a sepsuate them inte their pure form. (h) Investigate any patented catalytice process that will improve selectivity. Show alko its PFD. (c) Leternine ratio of gas tecycle rale to the molar flow rale of inpul. (d) Develap a l'ED for the process based on the dala provided. (c) Identify useful products for this process. (f) Foonomic potential F.P is penerally evaluated in stages. The first stage EP 2;0 is EPI/o= \{product value\} + \{By-products value } \{Raw material costs } { Auxiliary material costs } \{Ecological costs }