Part 1: Introduction to Process Synthesis and Flow Sheeting

1.1 Case study

aromatics in the feed stream. By
1,3,5-cyclohexatriene or benzole
making good use of sulfolane as
commonly known as benzene with
solvent, that will dissolve, or dilute
molecular formula C₆H₆. Laboratory
other substances where it
evaluations indicate that benzene is
preferentially absorbs aromatics,
nominally photochemically reactive in
especially benzene. The solvent-to-
the atmosphere compared to the
vapor ratio should be controlled
reactivity of other hydrocarbons.
properly for optimum separation
Benzene is a by-product of oil-refining
process for benzene.
processes and can be found in crude
oils. This well-known organic Absorption column will undergo
compound functions as solvent and contact between benzene and solvent
chemical intermediate also used in that will help to withdraw a great
numerous chemical synthesis. [1] Start composition of benzene by the end of
from conversion of benzene to the system. One application of this
ethylbenzene, then to styrene and enrichment procedure is to use the
continue to switch into polystyrene. recycle to enhance the extractive
stripping process itself.

Some industries make use of

benzene to be marketed together with
The largest application of benzene other chemicals to produce plastics,
is preparation of phenol including resins, synthetic fibers, and nylon.
preparation of aniline for dyes and Natural parts of crude oil, gasoline and
dodecylbenzene for detergents. cigarette smoke likewise include
Alternatively, synthesis of benzene benzene. [2] Additionally, benzene
can be route into various unique properties are classified as a clear,
techniques. A mixed hydrocarbon colorless and flammable liquid with
stream including benzene, toluene, relatively high melting point. It is a
xylene, ethyl benzene and heavier liquid chromatic hydrocarbon by a
aromatics are first consideration for gasoline-like odor and has a molecular
this synthesis method. Benzene is the weight 78.11g/mol that takes the
preferred embodiment to be separated chemical formula of C6H6. [3]
from the other non-aromatics and
3
1.2 Process Flow Diagram (PFD-with detailed labeling)

Operating conditions

1. Initial feed of mixed hydrocarbon to the distillation column at 130°C, 800kPa absolute pressure
with 152951kg/hr flow rate.
2. Feed of benzene and other compounds to the absorption column at 77°C, 140kPa absolute
pressure with 29700kg/hr flow rate.
3. Solvent flow rate at the upper portion of the absorption column is 117940kg/hr at 66°C.
4. Benzene with composition 55.91wt% at 340kPa absolute pressure flow with 16990kg/hr rate at
the end of reaction.
5. Solvent-to-vapor ratio ranges from 1:1 to 5:1 by weight.
6. Distillation column compounds withdraw to absorption columns in vapor phase at 87°C. (Feed)

4
1.3.1 Overall processes stream is fractionated. Remaining
uncondensed vapor will be directly
Absorption refers to the transfer of transferred to the absorption column,
one or more gas phase components to but the liquid portion of overhead
a liquid phase that is mentioned to be stream is withdrawn to be returned to
soluble. Gas mixture purposely the distillation column as reflux with
contacts with a liquid compound to composition of benzene 22.65wt%.
dissolve one or more components of Next, the bottom part of the distillation
the gas mixture and yield solution of column is flow out that might be
gas compound in the liquid. While transferred to storage or another plant,
stripping is in the opposite direction of but some portion being heated up with
mass transfer because the liquid phase the reboiler returned back to the
becomes the gas phase, but both of column. Packing or trays distillation
these systems hold identical principles. columns will be helpful to promote
vapor and liquid contact that demand
It is necessary to perfectionate the for fractional distillation.
starting material when faced with two
requirements. Initially, when the Another embodiment prefers
starting aromatic material introduction of gasoline as the
concentration is not within the representative of mixed hydrocarbons
preferred range, or it is desired to stream at the feed stream of the
undergo a separation process between distillate column. Benzene and other
different aromatic compounds. non-aromatics compounds are
Initially, a mixed hydrocarbon was withdrawn through the upper portion
introduced to the first distillation in a partially condensed state of matter
column (D-101) at 130°C with 800kPa far from the prefractionation zone but
abs pressure that served to the liquid returns as reflux.
perfectionate the initial mixed
hydrocarbons stream to specially In addition, uncondensed
provide vapor stream for the overhead vapor is transferred to an
absorption column. Production of the extractive stripping zone where there
overhead stream will be withdrawn at will be direct contact between solvent
the upper portion of the distillation and the benzene and non-aromatics
column after the mixed hydrocarbon compounds. Important part here is

5
benzene preferentially absorbed by the lead to motor-gasoline blending pools
solvent and withdrawn from the and be transferred to the pool as a low-
extractive stripping zone together with benzene blending stock when benzene
the solvent through an aromatic rich happens to be removed from gasoline.
solvent stream.
Solvent will be in contact with
A vapor stream introduces a lower vapors that rise through the absorber
portion of absorber. The vapor stream as the solvent introduced by the
will begin to rise through the column solvent stream. Generally, the solvent-
toward the upper absorber portion. The to-vapor ratio should range from 1:1 to
upper portion of the absorber is 5:1 by weight. The aromatic
introduced with a solvent that will compounds will be absorbed by the
comprise the liquid extractive solvent during the contact. In the
stripping solvent then begin to travel meantime, the solvent rich in absorbed
from upper portion down to lower aromatic compounds that had reached
portion at 71°C. A raffinate stream the lower portion of the absorber may
that mostly comprises non-aromatic be withdrawn. All the withdrawn from
compounds will be withdrawn from aromatic rich solvent streams will be
the upper portion passed through the introduced to a benzene distillation
condenser. column (D-102) that functions to
separate the aromatic component and
Composition of non-aromatic the solvent component from each
components that are lighter than other. The feed of aromatic
benzene and in boiling range with compounds to the distillation column
benzene are 47.30wt% and 50.61wt%. is at 182092kg/hr. Based on the
For this part, benzene is also present differences in boiling point of these
with very low composition together two components, the distillation
with toluene. The raffinate vapor will column will effectively separate the
be condensed into raffinate liquid and aromatic from the solvent.
withdrawn toward the accumulator.
The previous raffinate liquid might be Most of the aromatic components
transferred to storage or other plants. of the aromatic rich solvent stream are
When a pump is used to withdraw composed from the withdrawal of
liquid raffinate, the benzene might distillate stream as overhead. Reflux

6
may be returned to the distillation may be transferred to the upper portion
column after the distillate stream of the absorption column (D-101) that
passed through condenser and will be cooled to an appropriate
accumulator as much as partially or temperature upon solvent feeding.
completely returned with lower flow Cooling process occurs by passing the
rate (8596kg/hr). A portion of the solvent stream through the heat
aromatics which is benzene may be exchangers that are able to increase or
sent to the storage with 73.54wt%, but decrease the temperature of certain
some other portion also might be components as they pass through it.
returned to the absorption column as
an aromatic recycle. This recycle 1.3.2 Functions of each equipment
aromatic is needed when the content of
aromatic in the vapor stream is lower i. Absorption column
than the optimum amount. The vapor Absorption column is a unit operation
stream that has a minor portion of that removes one or more components
aromatic is routed to an alternative of a gas stream from the gas mixture to
feed point above the bottom of the be absorbed onto a non-volatile liquid
absorber. called solvent.

ii. Reboiler
On the other hand, the mentioned
A reboiler is a type of heat exchanger
vaporized aromatic recycle earlier can
that provides heat to the bottom of
be either routed to mix with the feed
distillation columns. It boils the liquid
vapor stream or introduced separately
from the bottom of a distillation
into the first absorption column. The
column to generate vapors, then
need and amount of the aromatic
returns back the vapor to the column to
recycle will be altered under the
conduct the distillation operation.
particular circumstances. Mentioned
the distillation column, a solvent iii. Pump
stream being withdrawn from the A mechanical equipment that lifts
bottom column which separates into liquid from low pressure area to high
two paths. Firstly, the withdrawn pressure area and acts as a booster in
stream might be heated in the reboiler this network system. Due to low
and reintroduced back to the pressure at one side of the pump, the
distillation column. Another way is it pump will help to lift and push fluid
until reached desired points.
7
iv. Distillation column 1.4 Physical and chemical properties of benzene
Distillation column will separate the
feed stream into one top product
stream and one bottom product stream.
Properties Description
The purity of the upper and bottom
products stream determines the quality
of the separation performed by a
column. Molar mass 78.11 g/mol

v. Condenser
Condensers help to cool the
Density 875.6 kg/m³ at 20°C
component vapors of the mixture that
allow the vapors to condense to liquid
form and flow downwards if
necessary. Boiling point 80.08°C at 760 mmHg

vi. Accumulator
Helping to speed up a process to cope
Melting point 5.55°C
with extreme demand of using less
powerful pumps. Accumulator acts as
a safety device to prevent load from
being dropped in case of engine or Viscosity 0.604 mPa.s at 25°C

pump failure.

Latent heat of
33.83 kJ/mol at 25°C
vaporization

Specific heat capacity 1.74 J/g. K

Vapor pressure 94.8 mmHg at 25°C

8
Part 2: Technical specification of absorber for the selected process

2.1 Introduction and mechanism for absorption with the liquid or the solvent, and in
The process of absorption means other cases, it reacts with the liquid
that a substance captures and transforms chemically. The purpose of such
energy. The absorbent distributes the scrubbing operations may be gas
material it captures throughout the purification, removal of air pollutants
whole and adsorbent only distributes it from exhaust gases (product recovery)
through the surface. The process of gas or production of solutions of gases for
or liquid which penetrate into the body various purposes.
of adsorbent is commonly known as
absorption. Gas absorption (also known Gas absorption is usually carried
as scrubbing) is an operation in which out in vertical counter current columns.
a gas mixture is contacted with a The solvent is fed in at the top of the
liquid for the purpose of absorber, the gas mixture from the
preferentially dissolving one or more bottom. The absorbed substance is
components of the gas mixture and to washed out by the solvent, which is
provide a solution of them in the liquid. often recovered in a subsequent
Therefore, we can see that there is a stripping or desorption operation. The
mass transfer of the component of the absorber may be a packed column, plate
gas from the gas phase to the liquid tower, or simple spray column, or a
phase. [4] bubble column. The fundamental
physical principles underlying the
The solute so transferred is said to process of gas absorption are the
be absorbed by the liquid. Absorption, solubility of the absorbed gas and the
or gas absorption, is a unit operation rate of mass transfer. Information on
used in the chemical industry to both must be available when sizing
separate gases by washing or scrubbing equipment for a given application.
a gas mixture with a suitable liquid. One
or more of the constituents of the gas In standard packed absorption
mixture dissolves or is absorbed in the columns, a gas mixture travels up
liquid and can thus be removed from the through a gas absorption tower and the
mixture. In some systems, this gaseous solute is transferred to the liquid phase
constituent forms a physical solution and thus gradually removed from the
9
 gas. The liquid accumulates solute on embodiment which uses sulfolane, the
its way down through the column. raffinate stream is water washed to
Multicomponent mass-transfer effects, recover the sulfolane. The solvent
non-isothermal gas absorption, and content of the final raffinate pi duct can
axial dispersion effects result in thus be controlled to meet a desired
considerable departures from ideal flow solvent concentration target.
assumptions. Neglect of axial dispersion Sulfolane, for example, is often
results in an overestimation of the controlled to about 10 weight ppm, and
driving forces and may lead to an in some instances to less than 1 weight
unsafe design. Bubble tray absorption ppm. Absorber used in this process is
columns may be designed graphically the tray column utilizing valve trays
based on a so-called McCabe-Thiele with structured packing.
diagram. The required number of actual
plates, however, is larger than the The most useful concept of the
number of theoretical plates. process of absorption is given by two-
film theory. According to this theory,
2.2 Selected types of absorber & solvent material is transferred in the bulk of
In this project we will be removing phases by convection currents, and
benzene from gasoline blending stocks. concentration differences are regarded
A mixed hydrocarbon feed is distilled to as negligible except in the vicinity of
separate benzene and non-aromatic the interface between the phases. On
components from non-benzene aromatic either side of this interface, it is
components. The benzene is then supposed that the currents die out and
separated from the non-aromatic that there exists a thin film of fluid
components by an absorber. The non- through which the transfer is affected
aromatic components and optionally the solely by molecular diffusion. This film
non-benzene aromatic components may will be slightly thicker than the laminar
be blended into motor gasoline. sub-layer, because it offers a resistance
equivalent to that of a whole boundary
The raffinate withdrawn from the layer.
absorber may contain some solvent.
This solvent may be recovered from the According to Fick’s Law the rate of
raffinate by various techniques such as transfer by diffusion is proportional to
distillation or water wash that are best the concentration gradient and the area
suited for such service. In the preferred of interface over which the diffusion is
10
 occurring. Fick’s Law is limited to Some advantages of using packed
cases where the concentration of the columns are that they require low
absorbed component is low. [5] At high pressure drop, and small diameters are
concentrations, bulk flow occurs and the possible. Packed columns can handle
mass transfer rate, which is increased. foaming systems. It has low capital,
The direction of transfer of material operating and maintenance cost. Packed
across the interface is not dependent columns are made with simple
solely on the concentration difference, construction and they can handle
but also on the equilibrium relationship. corrosives due to their corrosion-
resistant packing. They reduce back
Thus, for a mixture of ammonia or mixing in comparison to spray columns.
hydrogen chloride and air which is in They also have better mass transfer than
equilibrium with an aqueous solution, in spray columns. The disadvantages of
the concentration in the water is many packed columns include fewer stages
times greater than that in. the air. There compared to the other columns. The
is a very large concentration gradient channeling must be controlled by
across the interface, although this is not redistributing liquid. The packed
the controlling factor in the mass column also cannot handle liquid with
transfer, as it is generally assumed that high or low flow rates. They need to be
there is no resistance at the interface preferentially wetter to avoid reduction
itself, where equilibrium conditions will of the interfacial area to volume ratio.
exist. [6]

Absorbers are used in many

segments of the CPI and other
industries. The chemical industry uses
absorbers to capture acid gases, such as
hydrogen chloride and sulphur dioxide,
which are released in various processing
steps. The food industry eliminates
odorous emissions with absorbers.
2.3 Advantages and disadvantages of Other major purchasers are pulp mills,
absorption/absorber mines, steel mills and waste-to-energy
plants. [4]

11
2.4 Manipulated variables for the To minimize degradation of the
absorption process. solvent which recirculates through the
process, it is beneficial to operate the
The manipulated variables for the solvent recovery distillation column at
absorption process are the number of relatively low temperatures. Therefore,
aromatics fed to the absorber. Since the it may be necessary to operate the
aromatic recycle is predominantly distillation column under vacuum to
aromatic, increasing the amount of provide for adequate separation between
aromatic recycle will increase the the aromatic component and the solvent
relative number of aromatics fed to component. The maximum solvent
absorber. Therefore, if the concentration recovery temperature will vary
of aromatics in the vapor stream depending on the solvent, but for
flowing through were to drop below a sulfolane, the temperature at the bottom
predetermined optimum value, the of the solvent recovery distillation
amount of aromatic recycles flowing column should be maintained below
through should be increased to bring the 200 C if possible. Since solvent
relative number of aromatic compounds degradation is increased by oxygen,
fed to absorber up to the optimum sources of oxygen, such as air, are
value. preferably excluded from the system as
much as is practical. [7]
The returning of a portion of the
aromatic distillate stream to absorber 2.5 Typical problems related to the
may be accomplished by any suitable selected absorption process and
means, such as a valve. In the solutions.
embodiment a signal in the signal line
provides information about flow rate If the mixed hydrocarbon stream
and aromatic or benzene concentration comprises aromatics other than benzene
of the vapor stream. The information is and it is desired to separate those
provided to the controller which then aromatics from benzene, it is preferable
adjusts the valve through the control to fractionate the mixed hydrocarbon
line so that the flow of aromatic recycle stream before introducing a vapor
through will maintain the total amount containing benzene into the absorber.
of aromatic hydrocarbon (benzene) fed This prefractionation may be
to absorber in the desired range. accomplished by introducing the mixed
hydrocarbon stream to a distillation
12
column to separate benzene and other toluene and heavier components would
non-aromatic components from the be recovered in the bottoms stream. The
other non-benzene aromatics. For process may be used most
instance, a mixed hydrocarbon stream advantageously to separate benzene
comprising benzene and toluene from gasoline. Gasoline, a mixed
aromatics may be introduced to the hydrocarbon, may be fed to a
distillation column and fractionated into prefractionation column and separated
a distillate stream comprising most of into an overhead distillate stream
the benzene and non-aromatic comprising most of the benzene and
components of the mixed hydrocarbon non-aromatics. The other non-benzene
feed. aromatics may be withdrawn from the
bottom of the prefractionation column.
The heavier aromatics, such as The prefractionation column is a
toluene, and associated non-aromatics distillation column packed with either
would be withdrawn as a bottoms packing or trays and operated to
stream from the lower portion of the separate the gasoline feedstock by
distillation column. In a typical means well known in the fractionation
application more than 95% of the arts. The overhead stream from the
benzene introduced to this distillation prefractionation column will be
column would be recovered in the withdrawn as a vapor and partially
distillate while more than 95% of the condensed.

13
Part 3: Process Equipment Sizing & Costing
3.1.1 Mass balance for the absorber unit Overall Material Balance (Total mass):

Material balances express the 𝑚𝑚1 = 𝑚𝑚2 + 𝑚𝑚3

constraint of conservation of mass, as
Balance for component A:
applied to a process. It requires the
𝑚𝑚𝑚𝑚1 = 𝑚𝑚𝑚𝑚2 + 𝑚𝑚𝑚𝑚3
calculations of the quantity of all
materials entering and exiting any 𝑚𝑚1𝑋𝑋𝑋𝑋1 = 𝑚𝑚2𝑋𝑋𝑋𝑋2 + 𝑚𝑚3𝑋𝑋𝑋𝑋3

system or process which is based on the A total of three material balance can be
concept of the "law of conservation of obtain for the given process:
mass”. This law states that matter is
1. Total Balance: 𝑚𝑚1 = 𝑚𝑚2 + 𝑚𝑚3
neither created nor destroyed in the
2. A-Balance: 𝑚𝑚𝑚𝑚1 = 𝑚𝑚𝑚𝑚2 + 𝑚𝑚𝑚𝑚3
process and the total mass remains
3. B-Balance: 𝑚𝑚𝑚𝑚1 = 𝑚𝑚𝑚𝑚2 + 𝑚𝑚𝑚𝑚3
unchanged. The basic theory of material
balance calculations is to determine and
Equations for absorption column:
overcome a set of independent
equations involving the number of
Materials balance in the absorber
unknowns of compositions and mass
can be measured using the derivation of
flow rates of streams entering and
the general equation from single-stage
exiting the system or process.
equilibrium contact. We assume the
number of stages inside the absorption
Material Balance Equation for
tower using index N. Both the streams
nonreactive process, the process occurs
entering and leaving are in equilibrium.
at steady-state condition, and it does not
The two passing streams can be related
involve any chemical reaction. So, the
by the material balance or operating
equation for material balance:
line.
Input = Output

The equation can be used for: Overall Balance on all stages:

𝐿𝐿0 + 𝑉𝑉n+1 = 𝐿𝐿1 + 𝑉𝑉1 = 𝑀𝑀
1. The total mass that enters and
Overall Component Balance, A, B or C:
leaves the process.
𝐿𝐿𝐿𝐿o + 𝑉𝑉n+1𝑌𝑌n+1 = 𝐿𝐿xn + 𝑉𝑉n1 𝑌𝑌1 =
2. The mass of individual
Mxm
components that enter and leave the
process.

14
3.1.2 Calculations of Mass Balance BZ (78.11) 38.73 10.77 39.16
TL
2.12 2.00 2.14
Liquid flowrate = 29700kg/h (feed) + (92.141)

117940 kg/h (solvent) Heavy - - -

Sulfolane -
Vapor flowrate = 11360 kg/h (recycles) 0.06 86.30
(120.17)
input (wt%) percentage:
Water 0.02
component feed solvent recycles 1.06 0.31
(18.015)
Non-A light
45.10 - 7.20 G L L
(68.12)

BZ (78.11) 53.16 - 68.99 The since in the absorption column are

TL (92.141) 1.73 - 23.70 process to focus on channeling the
Heavy - - - liquid output to the heat exchanger so
Sulfolane the mass balance is on the liquid
- 99.35 -
(120.17) condition at the output.

Water The benzene output in liquid condition:

- 0.65 0.11 43420 (0) + 135760 (0.1077) + 22990
(18.015)
(0.3916) = Mass output
L L G
Mass output = 23624.236 kg/h

Benzene input in liquid and gas

Mass balance for benzene in the
condition:
absorption column:
29700 (0.5316) + 117940 (0) + 11360
Mass input ≈ Mass output
(0.6899) = Mass input
Mass input = 23625.784 kg/h
3.2.1 Estimation of absorber tower sizing

In this case the pack columns are

Vapor flowrate = 43420 kg/h
used since the liquid-vapor process
Liquid flowrate = 135760 kg/h + 22990
needs many liquid and gas compositions
kg/h
to meet efficiency of the process. Since
Output (wt%) percentage:
the benzene was quite corrosive
Component Light
Upper Bottom gaseous, the Raschig rings which were
raffinate
Non-A 50.60 made from ceramic material were taken

light 58.03 0.53 in consideration during calculation.

(68.12) Packing factor of Raschig rings of 2

15
 inches. Inputting 0.6 and 0.8 for 𝑥𝑥1 = 𝑚𝑚 𝐿𝐿𝑚𝑚
𝐺𝐺
𝑚𝑚
3.2.2 Estimation of number of transfer
gives values with 0.8 yielding the
unit (NOG) and number of stages
optimal values and more liquid flow
rate. Therefore, 0.8 is used.
Feed flow rate = 29700 kg/hr 𝐺𝐺
At 𝑚𝑚 𝐿𝐿𝑚𝑚 = 0.8, NOG = 8
Mol. Fraction in vapor = 94.8/760 = 𝑚𝑚

0.1247 mmHg Hence, number of stages is 8

Mol. Fraction in liquid = (1/78.11)/

(1/78.11+99/120.17) = 0.0153 mmHg 3.2.3 Estimation of column diameter

Slope, m = 0.1247/0.0153=8.1503 Estimation of column diameter [9]

Gas flow rate = 29700 kg/hr

Assuming 1% of benzene in flue gas: Converting to kg/s yields:

1 29700𝑘𝑘𝑘𝑘 1 ℎ𝑟𝑟 𝑘𝑘𝑘𝑘
Partial pressure = (760) = ℎ𝑟𝑟
× 3600𝑠𝑠 = 8.25 𝑠𝑠
100

7.6 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 Liquid flow rate = 117940 kg/h

117940𝑘𝑘𝑘𝑘 1 ℎ𝑟𝑟 𝑘𝑘𝑘𝑘
ℎ𝑟𝑟
× 3600𝑠𝑠 = 32.76 𝑠𝑠
Assuming 95% recovery of benzene by
the absorber: Packing size, dp = 2 in = 0.0508 m
Partial pressure of benzene at exit will Surface area of Packing, a = 92 m2/m3
be Packing factor, Fp = 65 ft = 213 m-1
7.6(0.05) = 0.38 mmHg Gas density at 20 ℃ = 875.6 kg/m3
𝑦𝑦1 𝑃𝑃 7.6 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚
𝑦𝑦2
= 𝑃𝑃1 = 0.38 𝑚𝑚𝑚𝑚𝑚𝑚𝑚𝑚 = 20 Liquid density = 1.2606 kg/m3
2
Liquid viscosity = 0.01034 kg/ms

It is suggested to make the value of

𝐺𝐺 𝑉𝑉𝑉𝑉 𝜌𝜌𝜌𝜌 41.52 1.2606
𝑚𝑚 𝐿𝐿𝑚𝑚 is in between 0.6 and 0.8, so it 𝐹𝐹𝐿𝐿𝐿𝐿 = �𝜌𝜌𝜌𝜌 = � =
𝑚𝑚 𝐿𝐿𝐿𝐿 119.39 875.6

will be resulted to the optimum values 0.0132

[8].
0.8𝜌𝜌𝜌𝜌(𝜌𝜌𝜌𝜌−𝜌𝜌𝜌𝜌)
𝑉𝑉𝑤𝑤 = � 𝜇𝜇𝜇𝜇 0.1
=
13.1𝐹𝐹 𝑝𝑝 � 𝜇𝜇𝜇𝜇 �

From material balance:

0.8(1.2606)(875.6−1.2606)
𝐿𝐿𝑚𝑚 𝑥𝑥1 = 𝐺𝐺𝑚𝑚 (𝑦𝑦1 − 𝑦𝑦2 ) � 0.1 = 0.3171 kg/m2s
10×−3
13.1(213)� �
0.01034
𝐺𝐺𝑚𝑚
𝑥𝑥1 = (0.01 × 0.95) =
𝐿𝐿𝑚𝑚
𝑚𝑚 𝐺𝐺𝑚𝑚
8.1503 𝐿𝐿𝑚𝑚
(0.1094)

16
 Column area required DL = Liquid phase diffusivity, m2/s
41.52
= 0.3171 = 130.94 𝑚𝑚2
1
1.2606
Column diameter 𝐾𝐾𝐿𝐿 �
0.01034×9.81
3
� =
2 −1
4 4 119.39 0.01034
= �𝜋𝜋 𝑎𝑎 = �𝜋𝜋 (130.94) = 12.91 𝑚𝑚 0.0051 �
468.37×0.01034
3
� �
1.2606×1.7×10 −9 �
2
(92 ×

50.8 × 10−3 )0.4

2.3171 KL = 0.0051(8.4704)
3.2.4 Estimation of column height
(4.5525x10-2) (1.8529) = 7.8007x10-5
m/s
Estimation of column height [9]
R = 0.08314 bar m3/Kmol.K
Mass transfer coefficients at vapor
Surface tension of liquid at 200C =
phase:
70x10-3N/m
1
𝐾𝐾𝐺𝐺 𝑅𝑅𝑅𝑅 𝑉𝑉𝑉𝑉 0.7 𝜇𝜇𝜇𝜇 3
Gravitational force, g = 9.81 m/s2 𝑎𝑎𝑎𝑎𝑉𝑉
= 𝐾𝐾5 �
𝑎𝑎𝑎𝑎𝑎𝑎
� �
𝜌𝜌𝜌𝜌𝜌𝜌𝜌𝜌
� (𝑎𝑎𝑎𝑎𝑝𝑝 )−.2.0
Surface area of Packing, a = 92 m2/m3 Where:
Effective area, aw [10], K5 = 5.23 for packing size above 15 mm
𝑎𝑎𝑤𝑤 𝜎𝜎𝜎𝜎 𝐿𝐿𝐿𝐿 0.1 𝐿𝐿𝐿𝐿 2 −0.05 𝐿𝐿𝐿𝐿 2 0.2
𝑎𝑎
= 1 − exp �−1.45 ( )0.75 (
𝜎𝜎𝜎𝜎 𝑎𝑎µ𝐿𝐿
) ( 2 )
𝜌𝜌 𝐿𝐿𝐿𝐿
( 𝜎𝜎 𝑎𝑎 ) �
𝜌𝜌𝜌𝜌 𝐿𝐿
KG = Gas film mass transfer coefficient,

Where: Kmol/m2s
𝐾𝐾𝐺𝐺 (0.08314)(363)
𝜎𝜎𝜎𝜎 = Critical surface tension for the =
(92)(1.45×10−5 )
1
particular material for metal = 75 N/m 41.52 0.7 10×−3 3
5.23 � � � � (92(50.8 ×
(92)(10×−3 ) (875.6)(1.45×10−5 )
𝜎𝜎𝜎𝜎 = Liquid surface tension, N/m
10−3 ))−.2.0
𝑎𝑎𝑤𝑤
=1− 30.18𝐾𝐾𝐺𝐺
𝑎𝑎
= 5.23(14.3922) (0.9235)
75×10−3 0.75 119.39 0.1 119.392 119.392 1.334×10−3
exp �−1.45 ( ) ( ) ( )−0.05 ( )0.2 �
70×10−3 92×10−3 875.62 (9.81) 875.6(70×10−3 )∗92
(0.0458)
aw = a (5.0910) = 92×5.0910
2 3
KG = 1.4072×−4 kmol/sm2bar
= 468.37 m /m
Gm = 0.0781 kmol/sm2
Lm = 0.1382 kmol/sm2
Mass transfer coefficients at liquid
phase:
The film transfer unit heights are given
𝜌𝜌𝜌𝜌 1
𝐾𝐾𝐿𝐿 (𝜇𝜇𝜇𝜇𝜇𝜇)3 =
by:
2 −1 𝐺𝐺𝐺𝐺
𝐿𝐿𝐿𝐿 3 𝜇𝜇𝜇𝜇 2 𝐻𝐻𝐺𝐺 = 𝐾𝐾𝐺𝐺𝑎𝑎 𝑤𝑤𝑃𝑃
0.0051 �𝑎𝑎 � �𝜌𝜌𝜌𝜌𝜌𝜌𝜌𝜌� (𝑎𝑎𝑎𝑎𝑝𝑝 )0.4
𝑤𝑤 𝜇𝜇𝜇𝜇
Lm
Where: 𝐻𝐻𝐿𝐿 = 𝐾𝐾𝐿𝐿
𝑎𝑎𝑎𝑎 𝐶𝐶𝑡𝑡

KL = Liquid film mass transfer

coefficient, m/s Where:
dp = Packing size, m = 2 in = 50.8 mm P = Column operating pressure, bar
17
 Ct = Total concentration, Kmol/m2s = 1802.98/1000.
55.6 kmol/m3 Current cost = original cost issued
Gm = Molar gas flow rate per unit cross (index value at present time/ index
2
sectional area, Kmol/m s value at original cost obtained)
Lm = Molar solvent flow rate per unit
cross sectional area, Kmol/m2s
3.3.2 Price for every equipment use to
run the separation:
0.0781
𝐻𝐻𝐺𝐺 = 1.4072×−4 ×468.37×1.013 = 1.1698
0.1382
𝐻𝐻𝐿𝐿 = 7.8007x10−5 ×468.37×55.6 = 0.0680 → Absorption column:
𝐻𝐻𝑂𝑂𝑂𝑂 = 1.1698 + 0.8(0.0680) = Bare vessel cost = $ 18 000
1.2242 Material: Stainless steels
Material factor: 1.7
Column height, Z = HOGNOG Pressure stand: 300 – 400 kPa
= 1.2242(8) Pressure factor: 1.0
= 9.7936 m ≈ 10 m Packed columns with Raschig rings
including support trays = $ 28 000
3.3.1 Cost estimation for selected
Number of stages: 8.0
equipment (inclusive column and
Diameter of column:12.91 m
adsorbent)
Height of column: 10 m
Column factor: 2.0
Price = ($ 18 000 x 1.7 x 1.0 x 1.0) + ($
28 000 x 2.0) = $ 86 600
Total cost = $ 86 600 (1802.98/1000) =
$ 156,138.07

→ Reboiler:
Number of reboiler: 2.0
The price used in cost estimation is Price = $ 50 000
issued from year 2007. [12] Total cost =$ 50 000 x 2.0 x

The average inflation rate from 2007 to (1802.98/1000) = $ 180,298.00

2021 is 1.80298%. [11]

Estimation of price ratio is ≈ → Pump:

18
Number of pumps: 5.0 (1802.98/1000) = $ 118,996.68
Price = $ 6,000 → Accumulator:
Total cost = $ 6,000 x 5.0 x Number of accumulators: 2.0
(1802.98/1000) = $54,089.40 Price = $264.58
Total cost = $ 264.58 x 2.0 x
→ Distillation tower: (1802.98/1000) = $ 954.06
Number of distillation column: 2.0
Estimated price = $ 85 000 → Heat exchanger:
Estimated total price = $ 85 000 x 2.0 x Number of heat exchanger: 3.0
(1802.98/1000) = $ 306,506.60 Pressure factor: 1.0
Price = $30 000 x 1.0 = $30 000
→ Condenser: Total cost = $30 000 x 3.0 x
Number of condensers: 3.0 (1802.98/1000) = $ 162,268.20
Price = $ 22 000 Overall Cost = $ 979,251.01
Total cost = $ 22 000 x 3.0 x

19
Part 4: Conclusion
4.1.1 Conclusion compounds, the absorption column
After all that has been said, this firstly performs its responsibility to
study concluded the main part of the undergo chemical processes which
absorption column in the separation demand compounds being absorbed by
process as one of the biggest its solvent to be separate from other
components for real-life industry unnecessary compounds and impurities
processes. The selected industrial if present. It is a reminder to bear that
process to produce concentrated every separation process not only
benzene with an absorber gives a route depends on the reactor by its own, but
to identify the absorption specification the operating conditions such as
under many specifications. Normally temperature, inlet ratio, solvent and
the industrial absorption column only feed flow rate, number of columns and
includes theoretical assumptions and pressure very influences the
claims but this study showed how composition of outlet stream at
much differs from real life absorption raffinate and rectifying section. Cost
columns compared to those estimation has helped us to
assumptions. The suitable types and comprehend how much a real-life
sizes of the absorption column can be absorption column reactor can cost
learned based on the actual operation industries’ personnel to spend
in the industry. especially during grace days before
maintenance but even worse during
As important as the distillation
any machine failure that may possibly
column to maintain impurity of pure
instigate a nearby compartment.

20
4.1.2 References
[1] Stephen J. Weininger, Engineering Handbook, Second Edition,
“Benzene and Beyond: Pursuing the CRC Press, 2004, pp. 65-1-65–5.
Core of Aromaticity,” USA, Jan. 2015. [8] Sinnott, R.K. (1999). Coulson
Accessed: Jun. 18, 2021. [Online]. & Richardson’s Chemical Engineering.
Available: 3th edition, Volume 6. Butterworth-
https://www.researchgate.net/publication Heinemann, Delhi, India, 587- 623, 807-
/277616058_Benzene_and_Beyond_Purs 816.
uing_the_C ore_of_Aromaticity. [9] N. Harry-Ngei A. A. Ujile, P.
[2] Jay A. Young, “Benzene.,” Rep. N. Ede (Dec 2019). EJERS, European
Carcinog., vol. 11, 2004, doi: Journal of Engineering Research and
10.1021/ed082p1769. Science Vol. 4, No. 12.
[3] M. T. Smith, “Advances in [10] Onda, K., Takeuchi, H. &
understanding benzene health effects Okumoto, Y. (1968). Mass transfer
and susceptibility,” Annu. Rev. Public coefficients between gas and liquid
Health, vol. 31, pp. 133–148, Apr. 2010, phases in packed columns. J. Chem.
doi:10.1146/annurev.publhealth.012809. Eng. Japan, 1(56).
103646. [11] Calculator.net, “Historical
[4] Mcllvaine Robert, “Adsorption Inflation Rate (CPI) for U.S.” Accessed:
and Absorption - Chemical June 18, 2021.
Engineering,” May 2012, Accessed: Jun. 15, 2021. https://www.calculator.net/inflation-
[Online]. Available:https://www.chemen
[5] Sunden Bengt, “Transport calculator.html
phenomena in Fuel cells,” 2019. [12] R. Woods, 2007. D.2
Accessed: Jun. 17, 2021. [Online]. Converting the FOB Cost into a Bare
Available: Module Cost. “Appendix D:
https://www.sciencedirect.com/topics/en Capital Cost Guidelines”.
gineering/ficks-law#:~:text=The Fick’s Accessed: June 18, 2021 from
diffusion law postulates, proportional to https://onlinelibrary.wiley.com/doi/pdf/1
the concentration gradient. 0.1002/9783527611119.app4
[6] Aladdin Rami, Absorption [13] “Appendix 1 equipment cost
process. Chemical Engineering Students estimation”. Accessed: June 18, 2021
Society, 2018. from:
[7] W. C. Corder and S. P. Hanson, https://link.springer.com/content/pdf/bb
“Other separation processes,” in The m%3A978-94-011-6544-0%2F1.pdf

21
4.1.3 Appendixes

Table 6.1 show the properties of first mixed hydrocarbon feed.

Table 6.2 show the properties of distillation column (D-102) feed from absorber

22
 Table 6.3 show first cycle of the absorption column

Table 6.4 show second cycle of the absorption column

23
Table 6.5 show the properties of final benzene concentration at raffinate of distillation
column (D-102)

24