PROCESS FLOW DIAGRAM OF EBMAX PLANT (AUTOCAD) STREAM TABLE BLOCK FLOW DIAGRAM OF EBMAX PLANT TEMPERATURE PHASE AND PRESSURE CHANGE PROCESS MATRIX CONDITIONS (PCM)
ASPEN PLUS STIMULATION
74
2.7.1 2.7.2 2.7.3 2.7.4
74 75 75 79
ASPEN PLUS FLOW DIAGRAM CONVERGENCE DATA STREAM REPORT BLOCK (EQUIPEMENT) REPORT
ii COMPREHENSIVE DESIGN ENGINEERING
EBMax Plant
CHAPTER 3: PROCESS DESCRIPTION 3.1
PROCESS CHEMISTRY OF ETHYLBENZENE
84
3.2
PROCESS CHOSEN CONSIDERATION
85
3.2.1 3.2.2 3.2.3 3.2.4 3.3
3.4
SAFETY AND ENVIRONMENTAL ISSUES ECONOMICAL INDICATOR MARKET RESEARCH FLEXIBILITY AND CONTROLLABILITY
85 86 87 87
DESCRIPTION OF PROCESS CHOSEN - EBMAX
88
3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6
88 88 89 89 89 90
ALKYLATION REACTION SYSTEM TRANSALKYLATION REACTION SYSTEM BENZENE COLUMN LIGHTS COLUMN ETHYLBENZENE COLUMN POLYETHYLBENZENE COLUMN
CRITICAL ASSESSMENT ON EBMAX
90
CHAPTER 4: ENERGY BALANCE AND UTILITY REQUIREMENTS 4.1
SUMMARY REPORT OF MASS BALANCE AND ENERGY BALANCE
94
4.2
UTILITIES
134
4.2.1 4.2.2 4.2.3
134 134 134
ELECTRICITY WATER STEAM
4.3
UTILITIES COST CALCULATION
136
4.4
HIGH & LOW PRESSURE STEAM BOILER
137
4.5
HEAT EXCHANGER NETWORK ANALYSIS
137
4.6
HEAT AND POWER INTEGRATION
138
4.6.1
140
CALCULATION STEPS OF PINCH TECHNOLOGY
4.7
AREA ESTIMATION OF HEAT EXCHANGERS
152
4.8
ANNUALIZED COST OF HEN
153
iii COMPREHENSIVE DESIGN ENGINEERING
EBMax Plant
CHAPTER 5: UNIT DESCRIBTION 5.1
CHEMICAL PLANT EQUIPMENT
156
5.1.1 5.1.2 5.1.3 5.1.4
156 157 158 160
REACTOR MASS TRANSFER EQUIPMENT HEAT TRANSFER EQUIPMENT AUXILLORY UNITS
5.2
EQUIPMENT CHOSEN
161
5.3
JUSTIFICATION OF EQUIPMENT CHOSEN
163
5.3.1 5.3.2 5.3.3 5.3.4
163 164 168
REACTOR MASS TRANSFER EQUIPMENT HEAT TRANSFER EQUIPMENT AUXILLORY UNITS
CHAPTER 6: DETAILED DESIGN OF EQUIPMENT & SPECIFICATION SHEETS 6.1
DESIGN BASIS DESIGN PARAMETERS DESIGN CRITERIA DESIGN METHOD DETAILED DESIGN OF REACTOR SELECTION OF REACTOR REACTOR SIZING MASS TRANSFER EFFECT HEAT TRANSFER EFFECT MECHANICAL ENGINEERING DESIGN ASPEN CALCULATION DATA FOR REACTOR
DETERMINING MINIMUM TRAYS DETERMINING MINIMUM REFLUX RATIO DETERMINING NUMBER OF EQUILIBRIUM TRAYS DETERMINING ACTUAL TRAYS-PLATE EFFICIENCY DETERMINING FEED-POINT LOCATION DETERMINING THE NET VAPOR VELOCITY AT DETERMINING THE HEIGHT OF THE COLUMN HEURISTICS IN DESIGNING DISTILLATION COLUMN
iv COMPREHENSIVE DESIGN ENGINEERING
EBMax Plant
6.2.5
6.3
6.4
6.5
ASPEN DATA FOR DISTILLATION COLUMN T-102
199
6.2.5.1 6.2.5.2 6.2.5.3
199 200 201
TEMPERATURE PROFILE COMPOSITION PROFILE REFLUX RATIO PROFILE
DETERMINING MINIMUM TRAYS DETERMINING MINIMUM REFLUX RATIO DETERMINING NUMBER OF EQUILIBRIUM TRAYS DETERMINING ACTUAL TRAYS-PLATE EFFICIENCY DETERMINING FEED-POINT LOCATION DETERMINING THE NET VAPOR VELOCITY AT FLOODING CONDITION AND THE DIAMETER OF COLUMN
203 203 203 204 204 205
6.3.4.7 6.3.4.8
DETERMINING THE HEIGHT OF THE COLUMN HEURISTICS IN DESIGNING DISTILLATION COLUMN
DETERMINING MINIMUM TRAYS DETERMINING MINIMUM REFLUX RATIO DETERMINING NUMBER OF EQUILIBRIUM TRAYS DETERMINING ACTUAL TRAYS-PLATE EFFICIENCY DETERMINING FEED-POINT LOCATION DETERMINING THE NET VAPOR VELOCITY AT FLOODING CONDITION AND THE DIAMETER OF COLUMN
210 211 211 211 212 212
6.4.4.7 6.4.4.8
DETERMINING THE HEIGHT OF THE COLUMN HEURISTICS IN DESIGNING DISTILLATION COLUMN
SUMMARY OF HEURISTICS FOR PROCESS VESSELS DESIGN OF SEPARATOR VESSEL T-101
STORAGE TANK
243
6.9.1 6.9.2
245 249
6.9.3 6.9.4 6.9.5
SHELL THICKNESS ESTIMATION BOTTOM THICKNESS ESTIMATION FOR FULLY SUPPORTED FLAT BOTTOM TANK DOME ROOF ESTIMATION LAMINATE THICKNESS ESTIMATION BETWEEN HEAD AND SHELL LIFTING LUGS DETAILS
250 250 251
6.10
LIST OF SUPPLIER AND COSTS OF PUMPS
254
6.11
SPECIFICATION SHEETS
255
CHAPTER 7: EQUIPMENT COST ESTIMATION 7.1
LIST OF EQUIPMENT
291
7.2
ESTIMATION OF PURCHASE COST AND BARE MODULE COST OF 292 EACH EQUIPMENT USING CORRELATIONS, EQUATIONS/GRAPHS AND CAPCOST
PROCESS SAFETY INFORMATION IN P&IDs AND THE POTENTIAL SAFETY CONTROL PROBLEM
11.2.2 11.3
RELIEF SYSTEM
403 407
11.3.0 11.3.1 11.3.2
INTRODUCTION HAZARD ASSOCIATED EQUIPMENT HAZARD STUDY
407 408 409
11.3.2.1 INTRODUCTION
409
HAZOP STUDY ON EQUIPMENTS
410
HAZAN
11.4.1 11.4.2 11.5
402 402
HAZARD IDENTIFICATION
11.3.3 11.4
11.2.1.1 PROCESS SAFETY INFORMATION 11.2.1.2 POTENTIAL SAFETY CONTROL PROBLEMS
421
FAULT TREE ANALYSIS (FTA) FAILURE MODES AND EFFECTS ANALYSIS (FMEA)
ENVIRONMENTAL PROTECTION AND ENVIRONMENTAL IMPACT
421 428 435
ANALYSIS (EIA)
11.5.1 11.5.2 11.5.3
11.6
11.7
ENVIRONMENTAL REQUIREMENTS WASTE DISCHARGE FROM PLANT TREATMENT OF WASTE EFFLUENT DURING NORMAL PLANT OPERATION
436 437 439
11.5.3.1 METHODS FOR SAFE SOLID WASTE DISPOSAL 11.5.3.2 METHODS FOR SAFE LIQUID DISPOSAL 11.5.3.3 METHODS FOR SAFE GASEOUS EMISSION
439 440 440
WASTE MANGEMENT AND TREATMENT PLANT
442
11.6.1 11.6.2 11.6.3 11.6.4 11.6.5 11.6.6
443 445 445 446 446 447
PRE-TREATMENT PRIMARY TREATMENT SECONDARY WASTEWATER TREATMENT ENVIRONMENT AND SURROUNDING AFFECT ENVIRONMENTAL AUDITING LIFE CYCLE ASSESSMENT
EMERGENCY SITUATION PROCEDURES
452
ix COMPREHENSIVE DESIGN ENGINEERING
EBMax Plant
11.8
THE HANDLING OF CHEMICAL ACCIDENTS WITHIN THE PLANT
454
11.9
PROCESS HAZARD CHECKLISTS
461
11.9.1 11.9.2
461 461
11.10
INTRODUCTUION GENERAL QUESTION REGARDING HAZARD CHECKLIST
PLANT STATY-UP AND SHUT DOWN
465
11.10.1 11.10.2
INTRODUCTION PHRASES OF THE START-UP
465 465
11.10.2.1MECHANICAL COMPLETION AND INTEGRITY 11.10.2.2 PRE-COMMISSIONING AND OPEARTIONAL TESTING 11.10.2.3 START-UP AND INITIAL OPERATION 11.10.2.4 PERFORMANCE AND ACCEPTANCE TESTING 11.10.2.5 POST COMMISSIONING
467 467 468 468 468
PLANT START UP PROCEDURES PLANT SHUT DOWN OPERATION
469
11.10.4.1 TYPES OF SHUT DOWN OPERATION 11.10.4.2 PLANT SHUT DOWN PROCEDURE
472 473
START-UP AND SHUT DOWN PROCEDURE FOR MAJOR UNIT GANTT CHART
477 480
11.10.3 11.10.4
11.10.5 11.10.6
CHAPTER 12: CONCLUSIONS AND RECOMMENDATIONS 12.1
CONCLUSION
487
12.2
RECOMMENDATIONS
487
REFERENCE
488 APPENDICES
APPENDIX A: CALCULATION OF MASS BALANCE
491
APPENDIX B: CALCULATION OF ENERGY BALANCE
512
APPENDIX C: UTILITIES CALCULATION
530
APPENDIX D: PURCHASED COST OF EQUIPMENT
532
APPENDIX E: SAMPLE CALCULATION OF OPTIMUM PIPE DIAMETER
