SIMULATION AND COST ESTIMATION USING ASPEN HYSIS V8.8 CYCLOHEXANE PRODUCTION PLANT
MD EJAZ ANWAR 2014A1PS572P
1. BACKGR BACKGROUN OUND D OF PROC PROCESS ESS Cyclohexane i is s a cycloalkane with cycloalkane with the molecular formula C formula C6H12 (abbreviated to Cy). Cy Cyclo clohex hexane ane is mai mainly nly use used d for the ind indust ustria riall pro produc ductio tion n of adipic acid and acid and caprolactam caprolactam whi hich ch ar are e pr prec ecur urso sors rs to nylon. nylon. Cy Cycl cloh ohex exan ane e is a colo co lour urle less ss fl flam amma mabl ble e li li!u !uid id wi with th a di dist stin inct ctiv ive e de dete ter" r"en ent# t#li like ke od odou ourr reminiscent of cleanin" products (in which it is sometimes used). $he simplified flowsheet for this process is shown below. %resh ben&ene and hydro"en feed streams are first fed throu"h a heater to brin" the streams up to reactor feed temperature and pressure conditions. $his feed mixture is then sent to a fixed#bed catalytic reactor where ' hydro"en molecules react with 1 ben&ene molecule to form cyclohexane. $his simulation will use an toic reactor block to model this reaction. $he toic block is a simple reactor mode mo dell wh whic ich h re re!u !uir ires es a us user er#s #spe peci cifi fied ed re reac acti tion on wi with th sp spec ecif ifie ied d li limit mitin in" " component and extent of reaction. $he reactor effluent stream is then sent to a flash tank to separate the li"ht and heavy components of the mixture. $he vapor stream comin" off the flash tank is recycled back to the feed mixture after a small pur"e stream is removed to prevent impurities from buildin" up in the system. $he ma*ority of the li!uid stream leavin" the flash tank "oes to a distillation column to purify the cyclohexane product while a small portion of the li!uid stream is recycled back to the feed mixture to minimi&e losses of ben&ene
Fig. 1 Cyclohexane Producion !roce"" !lan #lo$ "hee
%. Co" E"i&aion ' A""u&ing( No o# $or)ing hr" !er day' %* No. o# $ee)" !er year ' +% No. o# yr" o# o!eraion con"idered'%, $ee)" %.1 Sale"' 2.1.1 Products: -he a/or !roduc" #or&ed during he !lan o!eraion are Cyclohexane 0 ydrogen. ar)e co"" o# he"e &aerial" are' Cyclohexane 2,.%+ 34)g5 and ydrogen2$2.70/kg). Plan i" o!eraed #or %* hr". ( +% $ee)" !er year #or 1, year". Re"ul" generaed 6y A"!en Econo&ic Analy"er are'
Product Cyclohexane
Cost (US $/hr) Total Product Cost < 1=+> 34r
+'2.21,2-, 62-./-',
ydrogen
-oal Sale" o# he !roduc 2co&!ued #or each year 6y earlier in!u daa o# !roduc co""5' Year Sales(US $) Year Sales(US $)
1 ''0000
6 1600000 0
2
3
4
5
1'200000 7
1'00000
1-,00000 !
1,'00000 10
1600000
1++00000
1,00000
1/,00000
-a6le 1. -oal Sale" #or each year %.% Ex!en"e"' 2.2.1 Equipments: Follo$ing are he e7ui!&en" re7uired in he !lan and he corre"!onding co" a" calculaed hrough A"!en Econo&ic Analy8er. Equipment
Cooler2E91,15 eaer 2E91,,5 Se!araor :91,, Con;er"ion Reacor 2CR:9 1,,5 ain -o$er2-9 1,,5
Total irect Cost(US$)
Equipment Cost(US$)
/'00
1+,00
66'00
11-00
/,000
21200
1,00
-,000
1++00
-2,00
2'00
1'600
-,600
+00
Re6oiler2-91,,5 Conden"er2-9 1,,5
-a6le %. -oal Direc and E7ui!&en Co" 2.2.2 !a" #aterials: -he ra$ &aerial" re7uired #or he Cyclohexane !roducion are Ben8ene( ydrogen. ar)e co"" o# he"e &aerial" are' Ben8ene 2,.%+ 34)g5( ydrogen2$2.70/kg).. No$( #lo$ rae" o# he"e &aerial" $ere Ben8ene 2 +10./,2'1 3H5( ydrogen2+2+./,2'1 3H) . Plan i" o!eraed #or %* hr". ( +% $ee)" !er year #or 1, year" Re"ul" generaed 6y A"!en Econo&ic Analy"er are' !a" #aterial Ben8ene Feed
Cost (US $/hr)
Total !a" #aterial Cost < * 34hr 2.2. Utilities: Boh he ra$ 1'2.0+/,2 ydrogen &aerial" 6en8ene and ydrogen are heaed 6y he "ea& o he de"ired e&!eraure #or he reacion in he reacor 0 large a&oun o# elecriciy ex!en"e" ha" o 6e 6eared #or 1, yr". o!eraion o# !lan. Uiliy ex!en"e" calculaed in A"!en Econo&ic Analy"er are'
"esc r#%# on
4lect ricity Cooli n" ate r tea m <10 0=> tea m <-0 0=>
&l '#
a% e
++. 0, at er t e a m t e a m
0.0 ,02 +6
Un #%s
5 9 9 :;
',-.'0-
a% e Un#% s
Cos % er *o' r
5
,./+ 1'+ ,
99 :; 3H
6.0' '12
2./ 610 -6
5
5 3H
2-.1 02/ 1-
1., /' 2
5
5 3H
1.+ 1621
C os % U n# %s 7 83 H 7 83 H 7 83 H 7 83 H
Follo$ing oher co" $ere co&!ued hrough A"!en Econo&ic Analy"er' 2.2.% &ther E'penses ' %.%.*.1 Ca!ial Co"' ?or)ing Ca!ial < 321+,' invested in year 1
%.%.*.% O!eraing Co""' -oal O!eraing @a6our 0 ainenance Co" < 36,+-,0 each year -oal O!eraing Charge" < 2%+ o# -oal niial n;e"&en5 each year Plan O;erhead Ex!en"e" < 2+, o# -oal niial n;e"&en5 each year General 0 Ad&ini"rai;e Ex!en"e" < 2 o# -oal niial n;e"&en5 each year
Follo$ing are all he o!eraing ex!en"e" #or each year in 2US 35 a" e;aluaed hrough A"!en Econo&ic Analy"er'
yr. 1 2 3 4 5
1106/2
+lan% ,-erhea xense s 22,,,'
xense s '1/+0+
1+-'+2
',,'12
,0,'/
1+/60'
'6,/+2
,22'+
1-//1
'+6/,1
,'//,0
1/0,-1
'2,/
,,10,
Total &peratin Chares
yr. 6 7 ! 10
Total &peratin Chares 1/62,+ 2021-,
+lan% ,-erhea xense s '///0+
xense s ,+6+,/62++
2020/
110-'0 -11/0-
616'',
21--,6
-2-262
6'+0+1
220/
-'6//
6,,0+
-a6le =. -oal O!eraing Charge"( Plan O;erhead Ex!en"e" and General 0 Ad&ini"rai;e Ex!en"e" 2in US 35 No$( 2. !eenue Re;enue < Sale" Ca!ial Ex!en"e" O!eraing Ex!en"e" 9 Direc4ndirec Co"" De!reciaion Ex!en"e2hrough Sraigh @ine ehod5 #or each year < 1*+%, 3 -ax Rae < *, o# Earning" 6e#ore ax < ,.*2Re;enue De!reciaion5 Ca"h #lo$ #ro& !ro/ec each year < Earning" 6e#ore ax -ax Ex!en"e Follo$ing are all he Re;enue" and Ca"h #lo$" #or each year in 2US 35 a" e;aluaed hrough A"!en Econo&ic Analy"er' y r 1 2 3 4 5
!eenue #,,10000 6',0000 6+0000 +2-0000 ++20000
ax xense 0 220000 2-,0000 26'0000 220000
Cash &lo #,,10000 -00000 -''0000 -610000 ,/'0000
yr 6 7 ! 10
!eenue 2'0000 ++0000 /'-0000 //-0000 10600000
ax xense '2/0000 ',10000 '+'0000 '/0000 -2'0000
Cash &lo 6220000 6,,0000 6-0000 +100000 +-00000
-a6le *. Re;enue( -ax Ex!en"e and Ca"h #lo$" 2in US 35 2.% #easures o* Pro*ita+ilit,: Ne Pre"en :alue' U"ed in ca!ial 6udgeing o analy"e !ro#ia6iliy o# in;e"&en. Year + Year +
1 #-,/0000 6 +'0,10
2 #1+60000 7 '1106'00
3 +,06'' ,16-/00
4 2/+0000 ! +0-,,200
5 ,'60000 10 '6+/00
-a6le +. Ne Pre"en :alue 2in US 35 nernal Rae o# Reurn' U"ed o e;aluae he araci;ene"" o# a !ro/ec or in;e"&en < >,. Ne Reurn Rae ' ea"ure o# !or#olio or #undH" !er#or&ance < 1.,1 Pay9ou Period ' @engh o# i&e re7uired o reco;er he co" o# an in;e"&en < %.> year" Pro#ia6iliy ndex ' U"ed o 7uani#y a&oun o# ;alue creaed !er uni o# in;e"&en < 1.1>
=. Re#erence"'
1. h!"'44$$$.ici".co&4re"ource"4ne$"4%,,>4114,14,>+%,4cyclohexane9cx9!roducion9 and9&anu#acuring9!roce""4 %. h!"'44en.$i)i!edia.org4$i)i4Cyclohexane 3. !!"#$$"%&'())*&+)((!.'&,$'-'&(/("%&'!&6-6((( -%&(!&$
